Process Final Deliverables

OB3 Lot A Project
HYDRAULIC SIMULATION / LINE SIZING VERIFICATION REPORT
NIGERIAN NATIONAL PETROLEUM

CORPORATION
OB3 Lot A Project
HYDRAULIC SIMULATION/ LINE

SIZING VERIFICATION REPORT
A01 02/12/2020 Issued for Approval AIK ESO

R01 19/10/2020 Issued for Review AIK ESO
REV. DATE DESCRIPTION BY CHECKED APPROVED
DOCUMENT NO:
Client Project Area_EPCC Discipline Doc. Type Sequence- Rev.
NTC OB3 BPAS PRO DC Sheet
001 01
NGC -SODA-OBN_GCP-PRO-HYS -001
Doc. Control No.
OB3 Lot A Project
HYDRAULIC / LINE SIZING VERIFICATION REPORT
Contents
1 INTRODUCTION .................................................................................................................. 4
1.1 PROJECT BACKGROUND .............................................................................................. 4
1.2 OBJECTIVE ................................................................................................................... 4
1.3 DEFINITION .................................................................................................................. 5
1.4 ABBREVIATIONS .......................................................................................................... 5
1.5 REFERENCES ................................................................................................................ 5
1.6 SYSTEM OF UNITS........................................................................................................ 5
2 DESIGN BASIS AND CRITERIA ............................................................................................. 6
2.1 Pipe Design and Operating Data ................................................................................. 6
2.2 Fluid Design Parameters ............................................................................................. 6
2.3 Environmental Data .................................................................................................... 7
2.4 Assumptions ................................................................................................................ 7
2.5 Criteria ......................................................................................................................... 8
3 STUDY APPROACH AND METHODOLOGY .......................................................................... 9
3.1 Fluid PVT Analysis ........................................................................................................ 9
3.2 Steady State Hydraulic Analysis .................................................................................. 9
3.2.1 Simulation Model ............................................................................................... 10
NTC-OB3-BPAS-PRO-DC-001 Hydraulic Simulation / Line Sizing Verification Report

OB3 Lot A Project
4 RESULTS AND DISCUSSION .............................................................................................. 11
5 CONCLUSION .................................................................................................................... 13
6 APPENDIX ......................................................................................................................... 14
6.1 APPENDIX 1 Boundary Limit ...................................................................................... 14
6.2 APPENDIX 2: Velocity, Pressure and Temperature Profiles at 2BSCFD .................... 15
6.3 APPENDIX 3: Velocity, Pressure and Temperature Profiles at 1000MMSCFD .......... 17
6.4 APPENDIX 4: Velocity, Pressure and Temperature Profiles at 200 MMSCFD ........... 19
List of Tables
Table 2.1 Pipe Design Data ........................................................................................................ 6
Table 2.2 ELPS Fluid Composition .............................................................................................. 7
Table 2.3 Environmental Data ................................................................................................... 7
Table 3.1 Saturated Fluid Composition...................................................................................... 9
Table 3.2 Flow Simulation Boundary Conditions ..................................................................... 10
Table 4.1 Result Table .............................................................................................................. 11
List of Figures
Figure 4.1 Velocity versus Pressure Plot for a 2 BSCFD Flow rate ........................................... 12

OB3 Lot A Project
1 INTRODUCTION
1.1 PROJECT BACKGROUND
The Custody Transfer and Metering Station (CTMS) is a major component of the OB3
Lot A Project. The OB3 Project is one of the Federal Government of Nigeria (FGN)
funded Projects being executed in line with the Nigerian Gas Master Plan (NGMP) to
increase domestic gas supply for power generation & other industrial uses. It is
positioned to be a vital gas pipeline inter-connector linking the Eastern gas pipeline
network to the Western and Northern gas pipeline networks. The project entails the
construction of a 48”/36” x 130 km pipeline with a design capacity of 2.0 Billion
standard cubic feet per day (Bscf/d) of gas.
The CTMS Bypass pipeline project entails the construction of a 24” X 800Mtrs pipeline
system that will allow commissioning gas flow from the NAOC gas plant while the
CTMS facility is still under construction.
The CTMS bypass works include but is not limited to:
 Detailed Engineering Design for the OB3 CTMS Bypass Pipeline (3D PDMS Model,
Process Review, Piping General Arrangement, Piping Isometric, Instrumentation &
Control, Structural Design/Calculation, Process Design and P &ID, MTO e.t.c.)
 Procurement of LLIs for the CTMS Bypass Pipeline (Valves, Reducers, Tees, Gaskets,
Flanges, Spectacle blinds, Weldolets e.t.c.)
 Construction of the CTMS Bypass Pipeline (Personnel, Equipment, Security, FTO,

Accommodation, Welding Consumables and Structural support materials e.t.c.)
 Pre-commissioning and Commissioning of CTMS Bypass Pipeline
 Mobilization/Demobilization
1.2 OBJECTIVE
The objective of this document is to verify the adequacy of the 24” bye-pass line to
flow the maximum and minimum flow rate at the prevailing operating pressure.

OB3 Lot A Project
1.3 DEFINITION
COMPANY NNPC
CONTRACTOR BRADAMA INTERNATIONAL
FACILTY
SUBCONTRACTOR
1.4 ABBREVIATIONS
Acronyms Abbreviation
BSCFD Billion Standard cubic Feet per Day
ELPS Escravos Lagos Pipeline System
MMSCFD Million Standard Cubic Feet per Day
MTO Material Take Off
NA Not Available/ Accessible
PVT Pressure Volume Temperature
P&ID Piping and Instrumentation Diagram
Ref. Reference
WAGP West African Gas Pipeline
1.5 REFERENCES
Ref Document Number Document Title
1 NTC-OB3-BPAS-PRO-DW-001 PROCESS & INSTRUMENTATION DIAGRAM CTMS
BYPASS LINE
2 NA OB3 GAS PIPELINE
3 NA WAGP Quality Specification
4 API RP 14E Recommended Practice for Design and Installation of
Offshore Production Platform Piping Systems. 5th
Edition, 1991.
1.6 SYSTEM OF UNITS

Metric system of units shall be used unless otherwise specified. Inches may however
be used to quote line pipe and pipeline diameter.

OB3 Lot A Project
2 DESIGN BASIS AND CRITERIA

2.1 Pipe Design and Operating Data
The table below shows the pipe design and operating parameters.
Table 2.1 Pipe Design Data
Parameter Data
Length(m) 800
Elevation(m) 5.19
Service By pass for 36” Gas line
Nominal Size(inches) 24
Internal Diameter(in) 21.58
Wall thickness (mm) 30.96
Schedule 80
Material Carbon Steel
Thermal Conductivity(W/mK) 45
Absolute Roughness(mm) 0.045
Insulation Bare in Air
Operating Conditions
Pressure (barg) Temperature(⁰C)
Minimum Maximum Minimum Maximum
82 85 25 50
Design Conditions
Pressure (barg) Temperature(⁰C)
102 38
Flow Rate (MMSCFD)
Minimum Normal Maximum
200MMSCFD 1 BSCFD 2 BSCFD
2.2 Fluid Design Parameters

Typical ELPS gas composition which also meets the WAGP specification is used. The
properties are given in the table below.

OB3 Lot A Project
Table 2.2 ELPS Fluid Composition
Components Mole Fraction (%)

Methane 88.4359
Ethane 6.4118
Propane 1.1158
i-Butane 0.1688
n-Butane 0.2027
i-Pentane 0.0290
n-Pentane 0.0204
Hexane+ 0.5586
Nitrogen 0.3922
Carbon dioxide 2.6650
Total 100
Hypo Components Descriptions
Normal Boiling Point (⁰C) 79.02
Molecular Weight 86.18
Density (Kg/m3) 744.8
2.3 Environmental Data
The table below shows the environmental properties considered in the model.
Table 2.3 Environmental Data
Parameter Data
Minimum Air Temperature(⁰C) 21
Wind Speed (m/s) 1.67
2.4 Assumptions
 A pipe length of 800m was used as stated in the supporting documents.
However, the elevation profile of the 24" was not given so that of the 36"
pipeline was used (see attachment).

OB3 Lot A Project
 Also, pending the availability of the relevant isometric drawing, and

considering that the pipeline is a 24”line expanding to 36”, it shall be
assumed that the pipeline length is made up of 50% 24” and the remaining
50% 36” line.
2.5 Criteria
 The maximum gas velocity shall not exceed 60ft/s as specified in ref. 4.

OB3 Lot A Project
3 STUDY APPROACH AND METHODOLOGY

3.1 Fluid PVT Analysis
Considering that the fluid composition has no water fraction, the fluid was first
saturated at the pipeline condition (maximum temperature and pressure which
results in maximum water composition) using the saturator in HYSYS 10.0. This is
necessary to account for water and hence ensure proper hydraulic analysis in
PIPESIM.
The resulting fluid has the following composition.
Table 3.1 Saturated Fluid Composition
Components Mole Fraction (%)

Methane 88.23
Ethane 6.40
Propane 1.11
i-Butane 0.17
n-Butane 0.20
i-Pentane 0.03
n-Pentane 0.02
Hexane+ 0.56
Nitrogen 0.39
Carbon dioxide 2.69
Water 0.20
Total 100
The HYSYS saturation was done using Peng Robinson Equation of State as the fluid
package.
3.2 Steady State Hydraulic Analysis

The steady state hydraulic simulation was carried out using PIPESIM 2017.1. The
saturated fluid from HYSYS is used as the basis for the PIPESIM PVT.

OB3 Lot A Project
Both the minimum and the maximum pressure shall be used to investigate the
adequacy of the 24” bye-pass line at different flow rate.
To verify the adequacy of the 24 inch by pass, the velocity shall be investigated at
both the maximum and minimum pressure considering the three prevailing flow rates
of 200MMSCFD, 1000MMSCFD and 2000MMSCFD. While the expected worst case
shall be at the minimum pressure and maximum flow rate, an optimum operation
point shall be recommended based on the API recommended maximum velocity limit.
Where the velocity exceeds the API velocity criteria, the noise level at the prevailing
gas velocity is then calculated to check if it exceeds the industry standard noise power
level for human ear of 85 dB
The following boundary conditions were also used for the hydraulic simulation.
Table 3.2 Flow Simulation Boundary Conditions
Flow rate Departing Pressure Temperature

(MMSCFD) (BARG) (˚C)
200 85 50
82 25
1000 85 50
82 25
2000 85 50
82 25
3.2.1 Simulation Model

The model as developed on PIPESIM2017.1 is shown in figure 1 below. The battery
limit is the point of connection of the 24” bye-pass to the incoming 36” line through
the point where the 24” line is later connected to the departing 48” pipeline. A
schematic from the Ref. 1 is shown in appendix 1

OB3 Lot A Project
4 RESULTS AND DISCUSSION

A sensitivity analysis was carried out to investigate the effect of pressure and flow rate
on the gas velocity. The pipe was subjected to both the minimum and maximum
operating conditions (pressure and temperature) at the minimum, nominal and
maximum flow rates. Since the velocity in the 24” pipeline is expected to be higher, the
velocity at the 24” exit was checked against flow rates at these operating conditions
and the following results were obtained.
Table 4.1 Result Table
Flow rate Departing Departing Arrival Arrival Velocity Noise Comments

(MMSCFD) Pressure Temperature Temperature Pressure (ft/s) Level
O O
(BARG) ( C) ( C) (BARG) (dB)
200 85 50 27.32 84.99 10.71 61.0 *
82 25 21.90 82.00 10.89 61.4 *
1000 85 50 41.90 83.67 51.90 75.0 *
82 25 23.51 80.60 54.00 75.0 *
2000 85 50 44.69 81.67 96.75 80.42 **
82 25 22.13 78.53 101.36 80.82 **
* Velocity and noise level criteria met
** Velocity criteria not met but noise level criteria met
The results above show that for the maximum flow rate of 2BSCFD (2000MMSCFD),
subjected to the prevailing conditions, the velocity exceeds the recommended API
velocity of 60ft/s which implies that a pipe of 24 inches is too small based on API
recommendation only. However, since the API velocity recommendation was based on
noise level, the noise level at the flow rates are investigated to confirm that the level is
below the industry recommended sound power level of 85dB. From the above table,
while the recommended optimum flow rate is 1000MMSCFD based on API criteria, a
flow rate of 2BSCFD still meets the sound power level criteria as it is below 85dB as
seen in the result table above. The temperature, pressure and velocity profile are
shown in appendix 2 through to 4.

OB3 Lot A Project
It is also recommended that the length of the 24” portion of the pipeline be kept
minimal so as to keep the high velocity portion minimal.
Furthermore, an analysis was carried out to check for the minimum pressure necessary
to flow a flow rate of 2000MMSCFD without exceeding the recommended velocity of
60ft/s at the 24” pipe exit which corresponds with the point of sharp velocity drop on
the plot below. The result is displayed on the plot below
Figure 4.1 Velocity versus Pressure Plot for a 2 BSCFD Flow rate
From the result above, to operate at a maximum flow rate of 2BSCFD, a minimum
pressure of 150 barg is required.

OB3 Lot A Project
5 CONCLUSION
From the above analysis, the 24” bypass pipe can only flow an optimum flow of 1000
MMSCFD at the prevailing operating temperature and pressure without flaunting the
API RP 14E Criteria. The API recommended flow is therefore a maximum of
1000MMSCFD. However, considering the industry recommended noise level, a flow
rate of 2BSCFD can still be accommodated since its noise level does not exceed 85dB.

OB3 Lot A Project
6 APPENDIX
6.1 APPENDIX 1 Boundary Limit
Piping and Instrumentation Diagram
Piping Isometric

OB3 Lot A Project
6.2 APPENDIX 2: Velocity, Pressure and Temperature Profiles at 2BSCFD
PRESSURE PROFILE
TEMPERATURE PROFILE

OB3 Lot A Project
Velocity Profile

OB3 Lot A Project
6.3 APPENDIX 3: Velocity, Pressure and Temperature Profiles at 1000MMSCFD
Pressure Profile
Temperature Profile
OB3 Lot A Project
Velocity Profile

OB3 Lot A Project
6.4 APPENDIX 4: Velocity, Pressure and Temperature Profiles at 200 MMSCFD
Pressure Profile
Temperature Profile

OB3 Lot A Project
Velocity Profile

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OB3 Lot A Project

HYDRAULIC SIMULATION / LINE SIZING VERIFICATION REPORT

NIGERIAN NATIONAL PETROLEUM

OB3 Lot A Project

HYDRAULIC SIMULATION/ LINE

A01 02/12/2020 Issued for Approval AIK ESO

REV. DATE DESCRIPTION BY CHECKED APPROVED

HYDRAULIC / LINE SIZING VERIFICATION REPORT

1.1 PROJECT BACKGROUND .............................................................................................. 4

1.2 OBJECTIVE ................................................................................................................... 4

1.3 DEFINITION .................................................................................................................. 5

1.4 ABBREVIATIONS .......................................................................................................... 5

1.5 REFERENCES ................................................................................................................ 5

1.6 SYSTEM OF UNITS........................................................................................................ 5

2 DESIGN BASIS AND CRITERIA ............................................................................................. 6

2.1 Pipe Design and Operating Data ................................................................................. 6

2.2 Fluid Design Parameters ............................................................................................. 6

2.3 Environmental Data .................................................................................................... 7

2.4 Assumptions ................................................................................................................ 7

2.5 Criteria ......................................................................................................................... 8

3 STUDY APPROACH AND METHODOLOGY .......................................................................... 9

3.1 Fluid PVT Analysis ........................................................................................................ 9

3.2 Steady State Hydraulic Analysis .................................................................................. 9

3.2.1 Simulation Model ............................................................................................... 10

NTC-OB3-BPAS-PRO-DC-001 Hydraulic Simulation / Line Sizing Verification Report

HYDRAULIC SIMULATION / LINE SIZING VERIFICATION REPORT

4 RESULTS AND DISCUSSION .............................................................................................. 11

6.1 APPENDIX 1 Boundary Limit ...................................................................................... 14

6.2 APPENDIX 2: Velocity, Pressure and Temperature Profiles at 2BSCFD .................... 15

6.3 APPENDIX 3: Velocity, Pressure and Temperature Profiles at 1000MMSCFD .......... 17

Table 2.1 Pipe Design Data ........................................................................................................ 6

Table 2.2 ELPS Fluid Composition .............................................................................................. 7

Table 2.3 Environmental Data ................................................................................................... 7

Table 3.1 Saturated Fluid Composition...................................................................................... 9

Table 3.2 Flow Simulation Boundary Conditions ..................................................................... 10

Table 4.1 Result Table .............................................................................................................. 11

NTC-OB3-BPAS-PRO-DC-001 Hydraulic Simulation / Line Sizing Verification Report

HYDRAULIC SIMULATION / LINE SIZING VERIFICATION REPORT

The CTMS bypass works include but is not limited to:

 Construction of the CTMS Bypass Pipeline (Personnel, Equipment, Security, FTO,

 Pre-commissioning and Commissioning of CTMS Bypass Pipeline

NTC-OB3-BPAS-PRO-DC-001 Hydraulic Simulation / Line Sizing Verification Report

HYDRAULIC SIMULATION / LINE SIZING VERIFICATION REPORT

WAGP West African Gas Pipeline

1.6 SYSTEM OF UNITS

NTC-OB3-BPAS-PRO-DC-001 Hydraulic Simulation / Line Sizing Verification Report

HYDRAULIC SIMULATION / LINE SIZING VERIFICATION REPORT

2 DESIGN BASIS AND CRITERIA

2.2 Fluid Design Parameters

NTC-OB3-BPAS-PRO-DC-001 Hydraulic Simulation / Line Sizing Verification Report

HYDRAULIC SIMULATION / LINE SIZING VERIFICATION REPORT

Table 2.2 ELPS Fluid Composition

Components Mole Fraction (%)

2.3 Environmental Data

Table 2.3 Environmental Data

NTC-OB3-BPAS-PRO-DC-001 Hydraulic Simulation / Line Sizing Verification Report

HYDRAULIC SIMULATION / LINE SIZING VERIFICATION REPORT

 Also, pending the availability of the relevant isometric drawing, and

NTC-OB3-BPAS-PRO-DC-001 Hydraulic Simulation / Line Sizing Verification Report

HYDRAULIC SIMULATION / LINE SIZING VERIFICATION REPORT

3 STUDY APPROACH AND METHODOLOGY

The resulting fluid has the following composition.