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DOCUMENT REVISION HISTORY SHEET

REV STATUS DATE ISSUED UPDATE / AMENDMENT DETAILS

A - - NOT ISSUED

B IFR 17.07.2014 ISSUED FOR REVIEW


C IFA 25.09.2014 ISSUED FOR APPROVAL
00 AFD 16.11.2014 APPROVED FOR DESIGN
01 AFD 29.12.2014 RE-APPROVED FOR DESIGN

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CONTENT

1. INTRODUCTION ................................................................................................... 9

1.1 Purpose ............................................................................................................................................................ 9

1.2 Scope ................................................................................................................................................................ 9

1.3 Definitions and Abbreviations ..................................................................................................................... 10


2. REFERENCE DOCUMENTS .............................................................................. 11
3. CRUDE OIL EXPORT PIPELINE ........................................................................ 12

3.1 Description .................................................................................................................................................... 12

3.2 Fluid Composition ........................................................................................................................................ 13

3.3 Flow Correlations ......................................................................................................................................... 13

3.4 Pipeline Design Flow .................................................................................................................................... 13

3.5 Cases .............................................................................................................................................................. 13

3.6 Pipeline Heat Transfer Parameters ............................................................................................................ 14

3.7 Pipeline data.................................................................................................................................................. 14

3.8 Pipeline Length ............................................................................................................................................. 15

3.9 Pipeline Elevation ......................................................................................................................................... 16

3.10 Process Battery Limit Conditions ............................................................................................................... 18

3.11 In-plant Pressure Drop ................................................................................................................................ 18

3.12 Results ........................................................................................................................................................... 19

3.13 Conclusion ..................................................................................................................................................... 25


4. SALES GAS EXPORT PIPELINE ....................................................................... 26

4.1 Description .................................................................................................................................................... 26

4.2 Fluid Composition ........................................................................................................................................ 27

4.3 Flow Correlations ......................................................................................................................................... 27

4.4 Pipeline Design Flow .................................................................................................................................... 27

4.5 Cases .............................................................................................................................................................. 27

4.6 Pipeline Design Conditions .......................................................................................................................... 28

4.7 Pipeline Heat Transfer Parameters ............................................................................................................ 28

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4.8 Pipeline Data ................................................................................................................................................. 29

4.9 Pipeline Length ............................................................................................................................................. 29

4.10 Battery Limit Conditions ............................................................................................................................. 29

4.11 Pipeline pressure protection ........................................................................................................................ 30

4.12 In-plant Pressure Drop ................................................................................................................................ 31

4.13 Results ........................................................................................................................................................... 32

4.14 Conclusion ..................................................................................................................................................... 34


5. LPG EXPORT PIPELINE .................................................................................... 35

5.1 Description .................................................................................................................................................... 35

5.2 Fluid Composition ........................................................................................................................................ 36

5.3 Flow Correlations ......................................................................................................................................... 36

5.4 Pipeline Design Flow .................................................................................................................................... 36

5.5 Cases .............................................................................................................................................................. 36

5.6 Pipeline Design Conditions .......................................................................................................................... 37

5.7 Pipeline Heat Transfer Parameters ............................................................................................................ 37

5.8 Pipeline Data ................................................................................................................................................. 38

5.9 Pipeline Length ............................................................................................................................................. 38

5.10 Pipeline Elevation ......................................................................................................................................... 39

5.11 Battery Limit Conditions ............................................................................................................................. 41

5.12 Pipeline sizing criteria .................................................................................................................................. 41

5.13 In-plant Pressure Drop ................................................................................................................................ 42

5.14 Results ........................................................................................................................................................... 43

5.15 Conclusion ..................................................................................................................................................... 49


6. PRODUCED WATER PIPELINE......................................................................... 51

6.1 Process Description ...................................................................................................................................... 51

6.2 Flow Correlations ......................................................................................................................................... 51

6.3 Fluid Composition ........................................................................................................................................ 51

6.4 Pipeline Design Flow .................................................................................................................................... 51

6.5 Simulation Cases .......................................................................................................................................... 52


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6.6 Pipeline Design Conditions .......................................................................................................................... 52

6.7 Pipeline Heat Transfer Parameters ............................................................................................................ 53

6.8 Pipeline Diameter ......................................................................................................................................... 53

6.9 Pipeline Length ............................................................................................................................................. 54

6.10 Pipeline Elevation ......................................................................................................................................... 55

6.11 Battery Limit Conditions ............................................................................................................................. 57

6.12 Results ........................................................................................................................................................... 57

6.13 Conclusion ..................................................................................................................................................... 58


7. THIRD RIVER WATER PIPELINE ...................................................................... 59

7.1 Process Description ...................................................................................................................................... 59

7.2 Flow Correlations ......................................................................................................................................... 59

7.3 Fluid Composition ........................................................................................................................................ 59

7.4 Pipeline Design Flow .................................................................................................................................... 59

7.5 Cases .............................................................................................................................................................. 60

7.6 Pipeline Design Conditions .......................................................................................................................... 60

7.7 Pipeline Heat Transfer Parameters ............................................................................................................ 61

7.8 Pipeline Diameter ......................................................................................................................................... 61

7.9 Pipeline Length ............................................................................................................................................. 62

7.10 Pipeline Elevation ......................................................................................................................................... 63

7.11 Battery Limit Conditions ............................................................................................................................. 65

7.12 Results ........................................................................................................................................................... 65

7.13 Conclusion ..................................................................................................................................................... 66


8. CSSP SEAWATER PIPELINE ............................................................................ 67

8.1 Process Description ...................................................................................................................................... 67

8.2 Flow Correlations ......................................................................................................................................... 67

8.3 Fluid Composition ........................................................................................................................................ 67

8.4 Pipeline Design Flow .................................................................................................................................... 67

8.5 Cases .............................................................................................................................................................. 68

8.6 Pipeline Design Conditions .......................................................................................................................... 68


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8.7 Pipeline Heat Transfer Parameters ............................................................................................................ 69

8.8 Pipeline Diameter ......................................................................................................................................... 69

8.9 Pipeline Length ............................................................................................................................................. 70

8.10 Pipeline Elevation ......................................................................................................................................... 71

8.11 Battery Limit Conditions ............................................................................................................................. 73

8.12 Results ........................................................................................................................................................... 73

8.13 Conclusion ..................................................................................................................................................... 74


9. SUMMARY .......................................................................................................... 75
10. APPENDIX 1 – CRUDE OIL COMPOSITION ..................................................... 76
11. APPENDIX 2 – SALES GAS COMPOSITION .................................................... 77
12. APPENDIX 3 – LPG COMPOSITION ................................................................. 78

LIST OF TABLES AND FIGURES


Figure 3-1: Crude Oil Export Pipeline......................................................................................................................... 12
Table 3-2: Hydraulic Cases ......................................................................................................................................... 13
Table 3-3: Pipeline, Coating and Soil Characteristics ................................................................................................. 14
Table 3-4: Pipeline Data [Note 1]................................................................................................................................ 14
Figure 3-5: Crude Oil Pipeline Topography ................................................................................................................ 16
Figure 3-6: Crude Oil Pipeline Elevation .................................................................................................................... 17
Table 3-7: Process Battery Limit Conditions .............................................................................................................. 18
Table 3-8: In Plant Pressure Loss ................................................................................................................................ 18
Table 3-9: Crude Oil Pipeline Sizing Results [CASE A 45°C Crude Oil Inlet Temperature] at 684 MBOPD (+ 10%
margin) ........................................................................................................................................................................ 19
Table 3-10: Crude Oil Pipeline Sizing Results [CASE B 56°C Crude Oil Inlet Temperature] ................................... 19
Table 3-11: Crude Oil Pipeline Sizing Results [CASE A 45°C Crude Oil Inlet Temperature] at 650 MBOPD (no
margin) ........................................................................................................................................................................ 20
Table 3-12: Crude Oil Pipeline Sizing Results [CASE B 56°C Crude Oil Inlet Temperature] ................................... 20
Table 3-13: Oil Pipeline CAPEX ................................................................................................................................ 21
Table 3-14: Oil Pipeline OPEX [Note 1]..................................................................................................................... 22
Figure 3-15: Pipeline Diameter Comparison ............................................................................................................... 22
Table 3-16: Crude Oil Pipeline Data for API 5L X60 [Note 1]................................................................................... 23
Table 3-17: Crude Oil Inlet Temperature Sensitivity [Winter Ambient Temperature = 15°C] ................................... 24
Table 3-18: Crude Oil Inlet Temperature Sensitivity [Summer Ambient Temperature = 28°C]................................. 24
Figure 4-1: Sales Gas Export Pipeline ......................................................................................................................... 26
Table 4-2: Steady-state hydraulic cases ....................................................................................................................... 27
Table 4-3: Sales Gas Pipeline Mechanical Design Conditions .................................................................................... 28
Table 4-4: Pipeline, Coating and Soil Characteristics ................................................................................................. 28
Table 4-5: Pipeline Data for API 5L X60 [Note 1] ..................................................................................................... 29
Table 4-6: Process Battery Limit Conditions .............................................................................................................. 29
Table 4-7: Pressure Margins ........................................................................................................................................ 30
Table 4-8: In Plant Pressure Loss ................................................................................................................................ 31
Table 4-9: Sales Gas Export Pipeline results [Summer Soil Ambient Temperature = 28°C, API 5L X60] ................ 32
Table 4-10: Sales Gas Export Pipeline results [Winter Soil Ambient Temperature = 15°C, API 5L X60] ................ 33
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Table 4-11: Pressure Margins with PSV set at Design Pressure ................................................................................. 34
Figure 5-1: LPG Export Pipeline ................................................................................................................................. 35
Table 5-2: Steady-State Hydraulic Cases .................................................................................................................... 36
Table 5-3: LPG Pipeline Mechanical Design Conditions ............................................................................................ 37
Table 5-4: Pipeline & Soil Characteristics .................................................................................................................. 37
Table 5-5: Pipeline Data for API 5L X 60 [Note 1] .................................................................................................... 38
Figure 5-6: LPG Export Pipeline Topography ............................................................................................................ 39
Figure 5-7: LPG Export Pipeline Elevation................................................................................................................. 40
Table 5-8: Process Battery Limit Conditions .............................................................................................................. 41
Table 5-9: Pressure Margins ........................................................................................................................................ 41
Table 5-10: In Plant Pressure Loss (summer export flow case) .................................................................................. 42
Table 5-11: Case 1: Summer LPG Export Flow, 40°C operating temp, 28°C soil temp, API 5L X60 ...................... 43
Table 5-12: Case 2: Summer LPG Export Flow, 40°C operating temp, 15°C soil temp, API 5L X60 ...................... 44
Table 5-13: Case 3: Winter LPG Export Flow, 40°C operating temp, 28°C soil temp, API 5L X60 .......................... 45
Table 5-14: Case 4: Winter LPG Export Flow, 40°C operating temp, 15°C soil temp, API 5L X60 .......................... 46
Table 5-15: Case 5: Winter LPG Export Flow, 56°C operating temp, 28°C soil temp, API 5L X60 .......................... 47
Table 5-16: Case 6: Winter LPG Export Flow, 56°C operating temp, 15°C soil temp, API 5L X60 .......................... 48
Table 5-17: Pipeline ∆P for hydraulic cases for API 5L X60 pipeline grade .............................................................. 49
Table 5-18: Pressure Margins – 12” LPG pipeline diameter ....................................................................................... 50
Table 5-19: Pressure Margins – 10” LPG pipeline diameter ....................................................................................... 50
Table 6-1: Steady-State Hydraulic Cases .................................................................................................................... 52
Table 6-2: Produced Water Pipeline Mechanical Design Conditions.......................................................................... 52
Table 6-3: Pipeline & Soil Characteristics .................................................................................................................. 53
Table 6-4: Produced Water Pipeline Data ................................................................................................................... 53
Figure 6-5: Produced Water Pipeline Topography ...................................................................................................... 55
Figure 6-6: Produced Water Pipeline Elevation .......................................................................................................... 56
Table 6-7: Process Battery Limit Conditions .............................................................................................................. 57
Table 6-8: Produced Water Pipeline Hydraulics [winter soil temperature 15°C] ........................................................ 57
Table 6-9: Produced Water Pipeline Hydraulics [summer soil temperature 28°C] ..................................................... 58
Table 7-1: Steady-State Hydraulic Cases .................................................................................................................... 60
Table 7-2: TRW Pipeline Mechanical Design Conditions .......................................................................................... 60
Table 7-3: Pipeline & Soil Characteristics .................................................................................................................. 61
Table 7-4: Pipeline Data for API 5L X60 [Note 1] ..................................................................................................... 61
Figure 7-5: TRW Pipeline Topography ....................................................................................................................... 63
Figure 7-6: TRW Pipeline Elevation ........................................................................................................................... 64
Table 7-7: TRW Pipeline Mechanical Design Conditions .......................................................................................... 65
Table 7-8: Hydraulic results (winter soil temperature 15°C, API 5L X60) ................................................................. 65
Table 7-9: Hydraulic results (summer soil temperature 28°C, API 5L X60) .............................................................. 66
Table 8-1: Steady-State Hydraulic Cases .................................................................................................................... 68
Table 8-2: CSSP Seawater Pipeline Mechanical Design Conditions .......................................................................... 68
Table 8-3: Pipeline & Soil Characteristics .................................................................................................................. 69
Table 8-4: CSSP Seawater Pipeline Data for API 5L X60 .......................................................................................... 69
Figure 8-5: CSSP Pipeline Elevation ........................................................................................................................... 71
Figure 8-6: CSSP Pipeline Elevation ........................................................................................................................... 72
Table 8-7: CSSP Pipeline Mechanical Design Conditions .......................................................................................... 73
Table 8-8: Hydraulic results [winter soil temperature 15°C, API 5L X60] ................................................................. 73
Table 8-9: Hydraulic results [summer soil temperature 28°C, API 5L X60] .............................................................. 74
Table 9-1: Pipeline Sizing Summary ........................................................................................................................... 75

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HOLDS:

1. Seawater operating temperature data (assumed as 12-34°C as for TRW).


2. CSSP pipeline mechanical design temperature (50°C is an assumption only for the purposes
of calculating pipeline WT).
3. Available pressure at ICS tie-in to CSSP seawater pipeline ( L are to confirm).
4. Final pipeline alignment sheets.
5. Final CPF plant piping isometrics.
6. Vendor pressure drop data for fiscal metering.

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1. INTRODUCTION

( ), in partnership with the Company of , is


developing its upstream production facilities and infrastructure to meet a target of 1.2MMBOPD
of production in the 2 oil field in Southern . The field consists of two primary
reservoirs, and , which are developed as separate projects. It is envisaged that
the reservoir will produce 650MBOPD of the 1.2MMBOPD targeted from the entire
field.

WorleyParsons has been contracted to execute the FEED phase of the Development
Project. The development includes well pads, gathering systems, water injection facilities, gas
and water treatment, a gas turbine power plant, a light oil export pipeline and tank farm
upgrades, tie-ins to LPG and gas export systems and further expansion of supporting facilities
such as accommodation camps, security systems and expansion of the infrastructure as
necessary.
The Project aims to produce a comprehensive FEED Package in order to allow the progression of
the Project to the EPC (Execute) Phase.

1.1 Purpose

The purpose of this document is to provide basis, inputs and pipeline sizing for:
1. Crude Oil Export Pipeline to PS-1 Tank Farm
2. Sales Gas Export Pipeline ( CPF to IPS)
3. LPG Export Pipeline ( CPF to IPS)
4. Third River Water (TRW) Import Pipeline (IPS to CPF)
5. CSSP Sea Water Import Pipeline (ICS to CPF)
6. Produced Water Import Pipeline ( CPF to CPF Water Treatment tanks)

1.2 Scope

This hydraulic report covers steady-state hydraulic analysis for the six Export and Import
pipelines only. Transient analysis to calculate pressure surge is presented in Export Transient
Report 8015-0152-WP05-60-600-PC-RP-09002.

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1.3 Definitions and Abbreviations


CPF Central Processing Facility
CSSP Common Sea Water Supply Project
EPC Engineering, Procurement & Construction
ESP Electric Submersible Pump
FEED Front End Engineering Design
GTP Gas Treatment Plant
GTPP Gas Turbine Power Plant
HIPPS High Integrity Pressure Protection System
ID Inside Diameter
ICS Inter Connecting Station
IPS Intermediate Pigging Station
LPG Liquefied Petroleum Gas
MMBOPD Million Barrels of Oil per day
MBOPD Thousand Barrels of Oil per day
MMSCFD Million Standard Cubic Feet per Day
NPS Inches
OD Outside Diameter
STBOPD Stock Tank Barrels of Oil per day
SBBL/DAY Standard Barrels per Day
TRW Third River Water
WT Wall Thickness
3LPE 3-Layer Polyethylene

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2. REFERENCE DOCUMENTS

1. 8015-0152-WP05-12-000-PC-BD- Basis of Design CPF, GTP, Well Cluster


04001 Facilities and SRU
2. 8015-0152- -00-000-PC-BD-
Basic Engineering Design Data
00002
3. 8015-0152-WP05-61-600-PC-BD- Basis of Design Gathering, Water Injection,
09001 Export, & Import Pipelines
4. 8015-0152-WP05-22-201-PI-DB-
CPF Plot Plan
04001
5. 8015-0152-WP05-22-200-PC-HM- Heat and Material Balance for the Oil
04001 Treatment Plant
6. 8015-0152-WP05-21-240-PC-HM-
GTP Heat and Material Balance
05001
7. 8015-0150-WP01-31-750-PC-RP- Steady-state Hydraulics Report (Treated Water
00002 Pipeline)
8. 8015-0152-WP05-60-600-PL-DB- Export Network New 40” Oil Export Pipeline
09001 from CPF to PS-1
9. 8015-0152-WP05-60-600-PL-DB- Pipeline Route Map – Export Network Sales
09002 Gas, LPG Export and Water Supply Pipelines
10. 8015-0152-WP05- L-00-PL- Additional BVS (2 off) for Crude Oil Export
TQ-00048 Pipeline
11. 8015-0152-WP05- L-00-PR-
Export Pipelines
TQ-00010
12. 8015-0152-WP05-22-484-PC-DS- Process Datasheet for Water Injection Pump
04005 (LP)
13. 8015-0152-WP05- L-00-AL-
CSSP Design Basis MOM
MM-00166
14. API520 Part 1 Sizing and Selection of Pressure Relief Devices
15. 8015-0152-WP05-00-000-PC-DC-
Process Design Criteria
12001
Gas Transmission and Distribution Piping
16. ASME B31.8-2014
Systems
17. 8015-0152-WP05- L-00-AL- Minutes of Meeting from Weekly Pipeline
MM-00157_00 Meeting (W25)
18. 8015-0152-WP05-60-600-PC-RP-
Export Transient Report
09002
19. 8015-0152-WP05- L-00-PC-
LPG Pipeline Diameter
TQ-00082

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3. CRUDE OIL EXPORT PIPELINE

3.1 Description

Stabilized crude oil at production specification is stored in Stabilized Crude Oil Tanks (22-411-
00-TK-001A-C) at the CPF. The oil is exported to PS-1 tank farm by two pump stations in series
and a buried pipeline. In the first pump station [Export Crude Booster Pumps 22-411-00-P-
001A-E] there are five pumps in parallel (4 duty and one stand-by). In the second pump station,
[Export Crude Main Pumps 22-411-00-P-002A-E], there are five pumps in parallel (4 duty and
one stand-by). The exported oil flow is metered at the outlet of the CPF via Export Crude Fiscal
Metering Package (22-411-00-PK-001) prior to entering into the pipeline.
As per 8015-0152-WP05- L-00-PL-TQ-00048 [Ref.10], two additional Block Valve
Stations (BVS-5A and BVS-5B) are added to the Crude Oil Export Pipeline, and hence
a total of seven block valve stations located along the pipeline route. A schematic of the system
is shown in Figure 3.1 for reference.
Figure 3-1: Crude Oil Export Pipeline

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3.2 Fluid Composition

The composition of exported crude oil is referenced as per Stream 17 ‘Stabilized Crude to Export
Pipeline’ of Heat and Material Balance for the Oil Treatment Plant 8015-0152-WP05-22-200-
PC-HM-04001 [Ref.5]. The crude oil composition for the hydraulic analysis is provided in
Appendix 1.

3.3 Flow Correlations

Schlumberger PIPESIM Version 2011.1 with Moody pressure drop correlation (for single phase)
is applied. The compositional model in PIPESIM is applied for hydraulic line sizing of the crude
export pipeline.

Flow correlations:
Single phase : Moody
Thermodynamic Model:
Package : Multiflash Package
Equation of state : Peng Robinson
Viscosity : Pederson

3.4 Pipeline Design Flow

As referenced from Basis of Design 8015-0152-WP05-61-600-PC-BD-09001 [Ref.3], pipeline


design flow of 684 MSTBOPD (650 / 0.95 availability) plus 10% design margin.

3.5 Cases

A summary of the simulation cases for the crude oil export pipeline are provided below:

Table 3-2: Hydraulic Cases


Parameter Description Parameter
30” [Case 1]
36” [Case 2]
Pipeline Diameter (NPS)
40” [Case 3]
42” [Case 4]
28 (summer)
Ambient soil temperature (°C)
15 (winter)
45 [Case A]
Pipeline Inlet Temperature at CPF (°C)
56 [Case B]

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3.6 Pipeline Heat Transfer Parameters

The following Table 3-3 provides the details of the pipeline and soil characteristics. The
hydraulic study is based on Carbon steel pipeline with 3 mm corrosion allowance.
Table 3-3: Pipeline, Coating and Soil Characteristics
Data Parameter
Pipeline Material Carbon Steel
Carbon Steel Roughness 0.046 mm
Pipeline Thermal Conductivity 45 W/mK
Pipeline Burial Depth 1 m below ground from top of pipe [Note 2]
Soil Thermal Conductivity 1.12 W/mK
Soil Summer Temperature 28 °C
Soil Winter Temperature 15 °C
Pipeline Coating 3 Layer Polyethylene (3LPE)
Coating Thickness 3mm
Pipeline Coating Thermal Conductivity 0.414 W/mK
Wind Velocity 4 m/s
Note 1: Based on pipeline routing plan concrete coating is applicable for sections through wet
land area. For the purposes of hydraulic analysis, concrete coating has not been considered.
Note 2: In PIPESIM, pipeline is considered as fully buried 1m below ground from top of
pipeline.

3.7 Pipeline data

The pipeline OD, WT and ID data provided below is at the calculated design pressure for the
corresponding line size reviewed. The pipeline data is based on API 5L X65 pipe grade and 3mm
corrosion allowance.
Table 3-4: Pipeline Data [Note 1]
API 5L X65, CA 3mm
Design Nominal Pipeline Wall Pipeline
Design Temperature Pipeline OD Thickness ID
Pressure (buried) Diameter (mm)
(barg) (mm) (mm)
(°C) (NPS)
130 30 762 20.6 720.8
53 36 914.4 11.9 890.6
70
36 40 1016 10.3 995.4
31 42 1066.8 11.1 1044.6
Note 1: The above WT and ID data has been considered for the purposes of hydraulics.
Final WT and ID data is based on location class across the pipeline route.

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Note that as per Ref.17, the pipeline grade for the crude oil pipeline is API 5L X60. Refer to
Table 3.16 below for final OD, ID and WT data for the crude oil pipeline.

3.8 Pipeline Length

The crude oil pipeline length (87km) is referenced from the pipeline route map 8015-0152-
WP05-60-600-PL-DB-09001. For the calculation of pipeline pressure drop, an equivalent length
1.05 of the actual pipeline length has been applied to account for friction loss from pipeline
bends and fittings.

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3.9 Pipeline Elevation

Crude Oil pipeline elevation is shown in Figures 3.5 and 3.6 below.

Figure 3-5: Crude Oil Pipeline Topography

Elevation of Elevation of PS-1


Pipeline Direction
CPF Tank Farm

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Figure 3-6: Crude Oil Pipeline Elevation

16
Crude Oil Pipeline Elevation
15 Pipeline is buried 1m
below ground level
14

13

12

11

10

7 Ground Level
Elevation (m)
Pipeline
6

Datum 0
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95
-1

-2
Length (km)

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3.10 Process Battery Limit Conditions

The process operating pressure at the crude oil export pipeline inlet and outlet are summarized
below.

Table 3-7: Process Battery Limit Conditions


Parameter Description Parameter
Pipeline Inlet Pressure at CPF Calculated
Pipeline Inlet Temperature at CPF 45°C [Case A]
56°C [Case B]
Pipeline Outlet Pressure at PS-1 5 barg
Pipeline Outlet Temperature at PS-1 Calculated

3.11 In-plant Pressure Drop

Based on estimation of piping lengths from Plot Plan 8015-0152-WP05-22-201-PI-DB-04001


[Ref.4], the component of pressure loss in the plant piping is assumed as follows:

Table 3-8: In Plant Pressure Loss


Pressure Drop
Piping / Equipment
(bar)
Piping from booster pump outlet flange to B/L 2.0
Export Fiscal Metering 2.0
Total In-Plant Pressure Drop 4.0

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3.12 Results
The hydraulic results for the crude oil pipeline at 30”, 36”, 40” and 42” are summarized below. Note that in both cases, sizing is performed for winter
soil ambient temperature of 15°C (conservative for oil pipeline pressure drop).
Table 3-9: Crude Oil Pipeline Sizing Results [CASE A 45°C Crude Oil Inlet Temperature] at 684 MBOPD (+ 10% margin)
Pressure Pump
Pipeline Pipeline Pipeline
Nominal Pipeline Equivalent Pipeline Pipeline at PS-1 Arrival In Plant Discharge
Inlet pressure Inlet
Pipeline Size Length Length Flow velocity Tank Temp ΔP Pressure
Pressure drop Temp
(NPS) Farm [Note 1]
km km sbbl/day m/s barg barg bar °C °C barg Barg
30 3.5 89.9 84.8 45.5 93.8
36 2.3 35.4 30.4 42.5 39.4
87 91.4 752,632 5 45 4
40 1.8 23.0 18.0 41.7 27.0
42 1.6 19.4 14.4 41.5 23.4
Table 3-10: Crude Oil Pipeline Sizing Results [CASE B 56°C Crude Oil Inlet Temperature]
Pressure Pump
Pipeline Pipeline Pipeline
Nominal Pipeline Equivalent Pipeline Pipeline at PS-1 Arrival In Plant Discharge
Inlet pressure Inlet
Pipeline Size Length Length Flow velocity Tank Temp ΔP Pressure
Pressure drop Temp
(NPS) Farm [Note 1]
km km sbbl/day m/s barg barg bar °C °C barg barg
30 3.5 88.2 83.2 55.1 92.2
36 2.3 34.7 29.7 52.1 38.7
87 91.4 752,632 5 56 4
40 1.8 22.5 17.5 51.5 26.5
42 1.7 19.0 14.0 51.2 23.0
Note 1: Crude Oil Pump Discharge Pressure = Pipeline Inlet Pressure + In-plant Piping Loss (4 bar)
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Hydraulic results for additional sensitivity case at 650 MBOPD is provided in Tables 3.11 and 3.12 below.
Table 3-11: Crude Oil Pipeline Sizing Results [CASE A 45°C Crude Oil Inlet Temperature] at 650 MBOPD (no margin)
Pressure Pump
Pipeline Pipeline Pipeline
Nominal Pipeline Equivalent Pipeline Pipeline at PS-1 Arrival In Plant Discharge
Inlet pressure Inlet
Pipeline Size Length Length Flow velocity Tank Temp ΔP Pressure
Pressure drop Temp
(NPS) Farm [Note 1]
km km sbbl/day m/s barg barg bar °C °C barg Barg
30 3.0 69.7 64.7 44.0 73.7
36 1.9 28.4 23.4 41.6 32.4
87 91.4 715,000 5 45 4
40 1.6 18.9 13.9 40.9 22.9
42 1.4 16.2 11.2 40.6 20.2
Table 3-12: Crude Oil Pipeline Sizing Results [CASE B 56°C Crude Oil Inlet Temperature]
Pressure Pump
Pipeline Pipeline Pipeline
Nominal Pipeline Equivalent Pipeline Pipeline at PS-1 Arrival In Plant Discharge
Inlet pressure Inlet
Pipeline Size Length Length Flow velocity Tank Temp ΔP Pressure
Pressure drop Temp
(NPS) Farm [Note 1]
km km sbbl/day m/s barg barg bar °C °C barg barg
30 3.0 68.3 63.3 53.4 72.3
36 2.0 27.8 22.8 51.0 31.8
87 91.4 715,000 5 56 4
40 1.6 18.6 13.6 50.3 22.6
42 1.4 15.9 10.9 50.0 19.9
Note 1: Crude Oil Pump Discharge Pressure = Pipeline Inlet Pressure + In-plant Piping Loss (4 bar)

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To select the optimal pipeline diameter, a CAPEX / OPEX analysis is performed considering the
cost of pipeline steel, pumps and power (CAPEX) and cost of fuel gas, maintenance etc.
(OPEX). The below analysis is based on 45°C crude oil inlet temperature (Case A above).

Table 3-13: Oil Pipeline CAPEX

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Table 3-14: Oil Pipeline OPEX [Note 1]

Note 1: Fuel gas consumption applied in OPEX is equivalent fuel gas consumed to generate
power demand for the crude oil export pumps
Figure 3-15: Pipeline Diameter Comparison

Note 1: Currency is shown in USD.

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As shown in Figure 2 above, Case 3 (40” pipeline diameter) results in the overall minimum cost.

As detailed in Export Transient Report 8015-0152-WP05-60-600-PC-RP-09002_C [Ref.18], in


order to accommodate pipeline surge pressure, for 40” crude oil pipeline diameter, the
mechanical pipeline design pressure is 47 barg (within Class 300# rating). The pipeline OD, ID
and WT for API 5L X60 pipeline grade with 3mm corrosion allowance is summarized below:

Table 3-16: Crude Oil Pipeline Data for API 5L X60 [Note 1]
API 5L X60, CA 3mm
Nominal Pipeline Wall Pipeline
Design Design
Pipeline OD Thickness ID
Pressure Temperature
Diameter (mm) (mm) (mm)
(barg) (°C)
(NPS)
47 70 40 1016 11.13 993.7
Note 1: The above WT and ID data has been considered for the purposes of hydraulics.
Final WT and ID data is based on location class across the pipeline route.

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The crude oil arrival temperature at PS-1 tank farm is calculated for crude oil inlet temperature of 56°C and 45°C as shown below. This review is
based on pipeline WT of 11.13mm for 40” pipeline diameter at 47 barg design pressure and 70°C design temperature (data as per Table 3.16 above).

Table 3-17: Crude Oil Inlet Temperature Sensitivity [Winter Ambient Temperature = 15°C]
Pressure Pump
Nominal Pipeline Pipeline Pipeline In Discharge
Actual Equivalent Pipeline Pipeline at PS-1 Arrival Pipeline
Pipeline Inlet pressure Inlet Plant
Length Length Flow velocity Tank Temp ΔT (°C) Pressure
Size Pressure drop Temp ΔP
Farm [Note 1]
(NPS)
km km sbbl/day m/s barg barg bar °C °C °C barg barg
1.8 22.6 17.6 56 53.2 2.8 26.6
40 87 91.4 752,632 5 4
1.8 23.1 18.1 45 43.6 1.4 27.1

Table 3-18: Crude Oil Inlet Temperature Sensitivity [Summer Ambient Temperature = 28°C]
Pressure Pump
Nominal Pipeline Pipeline Pipelin In Discharge
Actual Equivalent Pipeline Pipeline at PS-1 Arrival Pipeline
Pipeline Inlet pressure e Inlet Plant
Length Length Flow velocity Tank Temp ΔT (°C) Pressure
Size Pressure drop Temp ΔP
Farm [Note 1]
(NPS)
km km sbbl/day m/s barg barg bar °C °C °C barg barg
1.8 22.7 17.7 56 51.5 4.5 26.7
40 87 91.4 752,632 5 4
1.8 23.1 18.1 45 41.9 3.1 27.1
Note 1: Crude Oil Pump Discharge Pressure = Pipeline Inlet Pressure + In-plant Piping Loss (4 bar)

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3.13 Conclusion

Based on the CAPEX/OPEX analysis, 40” diameter has been selected for the crude oil export
pipeline. For the winter case (15°C soil temperature) with 56°C crude oil temperature exiting the
CPF, the pipeline temperature drop is 4.5°C, and crude oil arrival temperature at PS-1 is 51.5°C.

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4. SALES GAS EXPORT PIPELINE

4.1 Description

The net sales gas from the outlet of Low Temperature Separator after process heat integration is
routed to the Sales gas compression unit for generating required pressure for product delivery. A
portion of the Sales Gas produced by CPF is consumed for fuel gas and power
generation demand. The net gas is exported via a pipeline which connects into the existing NPS
28 CPF sales gas export pipeline.
The sales gas export pipeline is designed to operate in reverse mode such that in the initial years,
dry sales gas can be utilized as fuel gas for the facility. Within the CPF, piping
will be provided to connect the reverse-flowing sales gas export line to the GTPP fuel gas
system.
Figure 4-1: Sales Gas Export Pipeline

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4.2 Fluid Composition

The export sales gas composition is referenced as per Stream 117 ‘Sales Gas to Export Pipeline’
of GTP Heat and Material Balance 8015-0152-WP05-21-240-PC-HM-05001 [Ref.6]. The Sales
Gas composition for the hydraulic analysis is provided in Appendix 2.

4.3 Flow Correlations

Schlumberger PIPESIM Version 2011.1 with Moody pressure drop correlation (for single phase)
is applied. The compositional model in PIPESIM is applied for hydraulic line sizing of the sales
gas export pipeline.

Flow correlations:
Single phase : Moody
Thermodynamic Model:
Package : Multiflash Package
Equation of state : Peng Robinson
Viscosity : Pederson

4.4 Pipeline Design Flow

As referenced from Basis of Design 8015-0152-WP05-61-600-PC-BD-09001 [Ref.3], pipeline


design flow is 365 MMSCFD plus 10% flow margin.

4.5 Cases

A summary of the simulation cases for the Sales Gas Export Pipeline are provided below.
Summer ambient soil temperature is considered to provide the most conservative pipeline
pressure drop.

Table 4-2: Steady-state hydraulic cases


Parameter Description Parameter
20
24
Pipeline Diameter (NPS)
28
30
28 (summer)
Ambient soil temperature (°C)
15 (winter)
Maximum Pipeline Inlet Temperature
70
at CPF (°C)

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4.6 Pipeline Design Conditions

Pipeline mechanical design conditions for the Sales Gas Export Pipeline from CPF will
be matched to the CPF sales gas export pipeline .

Table 4-3: Sales Gas Pipeline Mechanical Design Conditions


Pipeline Pipeline Mechanical Pipeline
Design Pressure Mechanical Design
Temperature
barg °C
Sales Gas Export Pipeline 94 85

4.7 Pipeline Heat Transfer Parameters

The following Table 4.4 provides the details of the pipeline and soil characteristics. Line sizing
and heat transfer is based on Carbon Steel pipeline with 3 mm corrosion allowance and 3LPE
coating.
Table 4-4: Pipeline, Coating and Soil Characteristics
Data Parameter
Pipeline Material Carbon Steel
Carbon Steel Roughness 0.046 mm
Pipeline Thermal Conductivity 45 W/mK
Pipeline Burial Depth 1 m below ground from top of pipe [Note 2]
Soil Thermal Conductivity 1.12 W/mK
Soil Summer Temperature 28 °C
Soil Winter Temperature 15 °C
Pipeline Coating 3 Layer Polyethylene (3LPE)
Coating Thickness 3mm
Pipeline Coating Thermal Conductivity 0.414 W/mK
Wind Velocity 4 m/s
Note 1: Based on pipeline routing plan concrete coating is applicable for sections through wet
land area. For the purposes of hydraulic analysis, concrete coating has not been considered.
Note 2: In PIPESIM, pipeline is considered as fully buried 1m below ground from top of
pipeline.

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4.8 Pipeline Data

The pipeline data based on API 5L X60 pipeline grade and 3mm corrosion allowance for the
pipeline diameter range is as follows:

Table 4-5: Pipeline Data for API 5L X60 [Note 1]


Design Pressure = 94 barg
Design Temperature = 85°C
API 5L X60, CA 3 mm
Nominal Pipeline Wall Pipeline ID
Pipeline OD Thickness (mm)
Diameter (NPS) (mm) (mm)
20 508 11.1 485.8
24 609.6 14.3 581.0
28 711.2 15.9 679.4
30 762 15.9 730.2
Note 1: The above WT and ID data has been considered for the purposes of hydraulics.
Final WT and ID data is based on location class across the pipeline route.

4.9 Pipeline Length

The length of the sales gas export pipeline is 9.43km referenced from the pipeline route map
8015-0152-WP05-60-600-PL-DB-09002 [Ref.9]. Note that consideration of elevation
differences has not been considered because it is expected that gas static pressure from elevation
is negligible. For the calculation of pipeline pressure drop, an equivalent length 1.05 of the actual
pipeline length has been applied to account for friction loss from pipeline bends and fittings.

4.10 Battery Limit Conditions

The process operating conditions for the sales gas pipeline inlet and outlet are summarized
below.

Table 4-6: Process Battery Limit Conditions


Parameter Description Parameter
Pipeline Inlet Pressure at CPF (barg) Calculated
Pipeline Inlet Temperature at CPF (°C) 70
Pipeline Outlet Pressure at
85.1
Tie-in (barg)
Pipeline Outlet Temperature at
Calculated
Tie-in (°C)
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4.11 Pipeline pressure protection

The sales gas pipeline pressure must be limited to 94 barg. As per ASME B31.8 “Gas
Transmission and Distribution Piping Systems” [Ref.16], the maximum allowable operating
pressure (MAOP) of the pipeline is equal to the design pressure determined in accordance with
Section 841.1.1 for steel. With pipeline wall thickness selected for 94 barg design pressure
(based on diameter, longitudinal joint factor, design factor, specified minimum yield strength,
wall thickness and temperature de-rating factor), the MAOP is therefore equal to 94 barg, which
cannot be exceeded in an overpressure event.
Hence the PSV at the sales gas compressor outlet must be set to 94 barg to safeguard the sales
gas pipeline from overpressure.

As per API 520 [Ref.14], for a conventional relief valve, maximum operating pressure must be
less than 90% of PSV set pressure (84.6 barg). With tie-in pressure at the Sales Gas pipeline of
85.1 barg, a conventional PSV is not possible.
A pilot operated PSV allows up to 98% of operating pressure before PSV simmer (refer table
below), and the pressure can operate closer to PSV set pressure.

Table 4-7: Pressure Margins


% of PSV set
Parameter Description Parameter
pressure
Pipeline Design Pressure (barg) 94 -
PSV Set Pressure 94 -
Maximum Operating Pressure for Pilot
92.1 98%
Operated PSV (barg)
Maximum Operating Pressure for
84.6 90%
Conventional PSV (barg)

Based on the use of a pilot operated PSV for sales gas compressor outlet:
PSV Set Pressure = 94 barg
Pressure at which PSV will simmer = 92.1 barg (98%)
Compressor to trip on PAHH = 91 barg (97%)
Maximum operating pressure = calculated below in Tables 4.10- 4.13.

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4.12 In-plant Pressure Drop

Based on estimation of piping lengths from Plot Plan 8015-0152-WP05-22-201-PI-DB-04001,


the component of pressure loss in plant piping from the compressor unit B/L to the pipeline inlet
is assumed as follows:

Table 4-8: In Plant Pressure Loss


Equipment / Piping Pressure Drop (bar)
Piping from Compressor Unit B/L to Pipeline Inlet 0.5
Export Fiscal Metering 1.0
Total In-Plant Pressure Drop 1.5

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4.13 Results

The hydraulic results for sales gas export pipeline diameters of 20”, 24”, 28” and 30” and API 5L X60 pipeline grade are summarized below.

Table 4-9: Sales Gas Export Pipeline results [Summer Soil Ambient Temperature = 28°C, API 5L X60]
Compressor
Compressor
Unit
Nominal Max Pipeline Pipeline Operating Unit
Pipeline Pipeline Inlet ΔT PSV Set Discharge
Pipeline Flow Pressure Inlet pressure ΔP/100m Temp at Discharge
Length velocity Temperature (°C) Pressure pressure as
Size at Tie-in Pressure drop Tie-in Pressure
a % of PSV
[Note 1]
Set Pressure
NPS km kg/h m/s barg barg bar bar °C °C °C barg barg barg
20 8.2 91.1 6.0 0.06 64.5 5.5 92.6 102%
24 410,272 5.8 87.6 2.5 0.02 65.5 4.5 89.1 98%
9.975 85.1 70 94
28 [Note 2] 4.2 86.2 1.1 0.01 65.8 4.2 87.7 96%
30 3.7 85.9 0.8 0.01 65.8 4.2 87.4 96%
Note 1: Compressor Unit Discharge Pressure = Pipeline Inlet Pressure + In-plant Piping Loss (1.5 bar)
Note 2: The basis for maximum export sales gas flow applied for pipeline sizing is for early in the production life (Year 2022) when ESP’s are not yet
installed i.e. when the power consumption to GTTP is low and maximum sales gas is exported

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Table 4-10: Sales Gas Export Pipeline results [Winter Soil Ambient Temperature = 15°C, API 5L X60]
Compressor
Compressor
Unit
Nominal Max Pipeline Pipeline Operating Unit
Pipeline Pipeline Inlet ΔT PSV Set Discharge
Pipeline Flow Pressure Inlet pressure ΔP/100m Temp at Discharge
Length velocity Temperature (°C) Pressure pressure as
Size at Tie-in Pressure drop Tie-in Pressure
a % of PSV
[Note 1]
Set Pressure
NPS km kg/h m/s barg barg bar bar °C °C °C barg barg barg
20 8.1 91.1 6.0 0.06 63.4 6.6 92.6 99%
410,272
24 5.7 87.5 2.4 0.02 64.4 5.6 89.0 95%
9.975 [Note 2] 85.1 70 94
28 4.2 86.2 1.1 0.01 64.6 5.4 87.7 93%
30 3.7 85.9 0.8 0.01 64.5 5.5 87.4 93%
Note 1: Compressor Unit Discharge Pressure = Pipeline Inlet Pressure + In-plant Piping Loss (1.5 bar)
Note 2: The basis for maximum export sales gas flow applied for pipeline sizing is for early in the production life (Year 2022) when ESP’s are not yet
installed i.e. when the power consumption to GTTP is low and maximum sales gas is exported

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4.14 Conclusion

28” pipeline diameter is recommended; which allows a 4% margin between operating pressure
and PAHH (compressor trip). However as demonstrated below, it is noted that the allowable
margins as per Process Design Criteria 8015-0152-WP05-00-000-PC-DC-12001 [Ref.15] cannot
be achieved given the required tie-in pressure at the sales gas export pipeline of 85.1
barg (refer Table 4.11 below).

Table 4-11: Pressure Margins with PSV set at Design Pressure


Margin from Margin
Parameter Description For 28” pipeline % of DP
PSV SP [Note 1]
Pipeline Mechanical Design
94 100% 0% 0%
Pressure (barg)
PSV Set Pressure 94 100% 0% 0%
PSV simmer 92.1 98% 2% -
PAHH 91 97% 3% 10%
Compressor discharge
87.7 93% 7% 20%
operating pressure (barg)
Note 1: Margins as per Process Design Criteria 8015-0152-WP05-00-000-PC-DC-12001
[Ref.15]

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5. LPG EXPORT PIPELINE

5.1 Description

LPG produced in the CPF is stored in mounded bullets and then pumped to the LPG
export line after fiscal metering. The LPG export pipeline connects into the 14”
LPG export pipeline as shown in Figure 5-1 below.
Figure 5-1: LPG Export Pipeline

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5.2 Fluid Composition

The export LPG composition is referenced as per Stream 384 ‘LPG to LPG Export Fiscal
Metering Package’ of GTP Heat and Material Balance 8015-0152-WP05-21-240-PC-HM-05001
[Ref.6]. The LPG composition for the hydraulic analysis is provided in Appendix 3.

5.3 Flow Correlations

Schlumberger PIPESIM Version 2011.1 with Moody pressure drop correlation (for single phase)
is applied. The compositional model in PIPESIM is applied for hydraulic line sizing of the crude
export pipeline.

Flow correlations:
Single phase : Moody
Thermodynamic Model:
Package : Multiflash Package
Equation of state : Peng Robinson
Viscosity : Pederson

5.4 Pipeline Design Flow

As referenced from Basis of Design 8015-0152-WP05-61-600-PC-BD-09001 [Ref.3], LPG


pipeline flow is 4,083 t/d (summer LPG export flow) and 4,907 t/d (winter LPG export flow).
Hence the pipeline is to be sized for the peak flow of 4,907 t/d plus 10% margin (5,398 t/d).

5.5 Cases

A summary of the simulation cases for the LPG Export Pipeline are provided below:

Table 5-2: Steady-State Hydraulic Cases


Piping / Equipment Parameter
8
Pipeline Diameter (NPS) 10
12
187,138 (summer LPG export flow)
Flow (kg/h)
224,898 (winter LPG export flow)
Ambient soil 28 (summer)
temperature (°C) 15 (winter)
Maximum Pipeline Inlet Temperature 40 (min operating temperature)
at CPF (°C) 56 (max operating tempature)

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5.6 Pipeline Design Conditions

Pipeline mechanical design conditions for the LPG Export Pipeline from CPF are
matched to the CPF sales gas export pipeline. Export Transient Report 8015-0152-
WP05-60-600-PC-RP-09002 (Ref.18] reviews the maximum surge pressure in the pipeline based
on 94 barg design pressure and 103.4 barg maximum surge pressure allowable by code (as per
ASME B31.4 Clause 403.3.4 Criteria for Transient Overpressure ‘pressure rise due to surges
and other variations from normal operations shall not exceed the internal design pressure at any
point in the piping system and equipment by more than 10%’).
Table 5-3: LPG Pipeline Mechanical Design Conditions
Pipeline Pipeline Mechanical Pipeline
Design Pressure Mechanical Design
Temperature
barg °C
LPG Export Pipeline 94 85

5.7 Pipeline Heat Transfer Parameters

Table 5-4 below provides details of the pipeline and soil characteristics. The hydraulic study is
based on Carbon steel pipeline with 3 mm corrosion allowance.
Table 5-4: Pipeline & Soil Characteristics
Data Parameter
Pipeline Material Carbon Steel
Carbon Steel Roughness 0.046 mm
Pipeline Thermal Conductivity 45 W/mK
Pipeline Burial Depth 1 m below ground from top of pipe [Note 2]
Soil Thermal Conductivity 1.12 W/mK
Soil Summer Temperature 28 °C
Soil Winter Temperature 15 °C
Pipeline Coating 3 Layer Polyethylene (3LPE)
Pipeline Thickness 3mm
Pipeline Coating Thermal Conductivity 0.414 W/mK
Wind Velocity 4 m/s
Note 1: Based on pipeline routing plan concrete coating is applicable for sections through wet
land area. For the purposes of hydraulic analysis, concrete coating has not been considered.
Note 2: In PIPESIM, pipeline is considered as fully buried 1m below ground from top of
pipeline.

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5.8 Pipeline Data

The pipeline data based on API 5L X60 pipe grade and 3mm corrosion allowance is as follows:

Table 5-5: Pipeline Data for API 5L X 60 [Note 1]


Design Pressure = 94 barg, Design Temperature = 85°C
API 5L X60, CA 3 mm
Nominal Pipeline Wall Pipeline ID
Pipeline OD Thickness (mm)
Diameter (NPS) (mm) (mm)
8 219.1 7.0 205.1
10 273.1 7.8 257.5
12 323.9 8.4 307.1
Note 1: The above WT and ID data has been considered for the purposes of hydraulics.
Final WT and ID data is based on location class across the pipeline route.

5.9 Pipeline Length

The length of the LPG export pipeline is 9.43km referenced from the pipeline route map 8015-
0152-WP05-60-600-PL-DB-09002 [Ref.9]. Equivalent applied is 1.05 of actual pipeline length
to account for friction loss from pipeline bends and fittings.

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5.10 Pipeline Elevation

LPG pipeline elevation is shown in Figures 5.6 and 5.7 below.


Figure 5-6: LPG Export Pipeline Topography

CPF Pipeline Direction IPS

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Figure 5-7: LPG Export Pipeline Elevation

LPG Pipeline Elevation


5 Pipeline is buried 1m
below ground level
4.5

3.5

Ground Level
Elevation (m) 2.5
Pipeline

1.5

0.5

Datum 0
0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5 5.5 6 6.5 7 7.5 8 8.5 9 9.5 10
Length (km)

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5.11 Battery Limit Conditions

The process operating conditions for the LPG pipeline inlet and outlet are summarized below.

Table 5-8: Process Battery Limit Conditions


Parameter Description Parameter
Pipeline Inlet Pressure at CPF Calculated
Pipeline Inlet Temperature at CPF 40°C
Pipeline Outlet Pressure at Tie-in 80 barg
Pipeline Outlet Temperature at Tie-in Calculated

5.12 Pipeline sizing criteria

HIPPS shall be installed at the LPG pump outlet to protect the LPG export pipeline against
overpressure. LPG pipeline size is selected to ensure 80 barg tie-in pressure into LPG
Export pipeline is met while maintaining maximum process operating pressure at the LPG pump
outlet at a suitable margin below the HIPPS set pressure.

Table 5-9: Pressure Margins


Parameter Description Parameter Difference
Pipeline Design Pressure (barg) 94 -
HIPPS Set Pressure (barg) 91 3%
Maximum Operating Pressure at
Calculated Calculated
LPG Pump Outlet (barg)

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5.13 In-plant Pressure Drop

Based on estimation of piping lengths from Plot Plan 8015-0152-WP05-22-201-PI-DB-04001


[Ref.4], the component of pressure loss in plant piping from the pump discharge to the export
pipeline inlet for the summer export flow case of 187,138 kg/h and winter export flow case of
224,898 kg/h is assumed as follows:

Table 5-10: In Plant Pressure Loss (summer export flow case)


Pressure Drop (bar)
Summer Winter
Equipment / Piping Export Flow Export Flow
Case Case
Piping from Pump P/L to Pipeline Inlet 1.0 1.45
Export Fiscal Metering 1.0 1.45
Total In-Plant Pressure Drop 2.0 1.9

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5.14 Results

Tables 5.11 and 5.12 below present the hydraulic results for the LPG export pipeline for summer LPG export flow (187,138 kg/h), at pipeline
diameters of 8”, 10”, and 12” and API 5L X60 pipeline grade.

Table 5-11: Case 1: Summer LPG Export Flow, 40°C operating temp, 28°C soil temp, API 5L X60
LPG Operating
Pressure
Flow Pump pressure Operating
Nominal at Tie-in Pipeline Pipeline Inlet Operating Pipeline HIPPS
Pipeline Pipeline ΔT Discharge as a % of pressure as a
Pipeline to Inlet pressure Temp at Design Set
Length (Summer velocity (°C) Pressure Mechanica % of HIPPS
Size Pressure drop Temp Tie-in Pressure Pressure
Case) l Design Set Pressure
Header
(Note 1) Pressure

NPS km kg/h m/s barg barg bar °C °C °C barg barg barg barg barg

8 2.9 95.5 15.5 38.7 1.3 97.5 104% 107%

10 9.90 187,138 1.8 80 84.8 4.8 40 38.3 1.7 86.8 94 92% 91 95%

12 1.3 81.9 1.9 38.2 1.8 83.9 89% 92%

Note 1: LPG Pump Discharge Pressure = Pipeline Inlet Pressure + In-plant Piping Loss (2 bar)

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Table 5-12: Case 2: Summer LPG Export Flow, 40°C operating temp, 15°C soil temp, API 5L X60
LPG Operating
Pressure
Flow Pump pressure Operating
Nominal at Tie-in Pipeline Pipeline Inlet Operating Pipeline HIPPS
Pipeline Pipeline ΔT Discharge as a % of pressure as a
Pipeline to Inlet pressure Temp at Design Set
Length (Summer velocity (°C) Pressure Mechanica % of HIPPS
Size Pressure drop Temp Tie-in Pressure Pressure
Case) l Design Set Pressure
Header
(Note 1) Pressure

NPS km kg/h m/s barg barg bar °C °C °C barg barg barg barg barg

8 2.8 95.5 15.5 36.9 3.1 97.5 104% 107%

10 9.90 187,138 1.8 80 84.7 4.7 40 36.4 3.6 86.7 94 92% 91 95%

12 1.3 81.9 1.9 36.1 3.9 83.9 89% 92%

Note 1: LPG Pump Discharge Pressure = Pipeline Inlet Pressure + In-plant Piping Loss (2 bar)

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Tables 5.13 to 5.14 below present the hydraulic results for the LPG export pipeline for winter LPG export flow (224,898 kg/h), at pipeline diameters of
8”, 10”, and 12”, API 5L X60 pipeline grade, at 40°C operating temperature.

Table 5-13: Case 3: Winter LPG Export Flow, 40°C operating temp, 28°C soil temp, API 5L X60
LPG Operating
Pressure
Flow Pump pressure Operating
Nominal at Tie-in Pipeline Pipeline Inlet Operating Pipeline HIPPS
Pipeline Pipeline ΔT Discharge as a % of pressure as a
Pipeline to Inlet pressure Temp at Design Set
Length (Winter velocity (°C) Pressure Mechanica % of HIPPS
Size Pressure drop Temp Tie-in Pressure Pressure
Case) l Design Set Pressure
Header
(Note 1) Pressure

NPS km kg/h m/s barg barg bar °C °C °C barg barg barg barg barg

8 3.4 102.3 22.3 39.1 0.9 105.2 112% 116%

10 9.90 224,898 2.2 80 86.9 6.9 40 38.7 1.3 89.8 94 95% 91 99%

12 1.5 82.7 2.7 38.5 1.5 85.6 91% 94%

Note 1: LPG Pump Discharge Pressure = Pipeline Inlet Pressure + In-plant Piping Loss (2.9 bar)

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Table 5-14: Case 4: Winter LPG Export Flow, 40°C operating temp, 15°C soil temp, API 5L X60
LPG Operating
Pressure
Flow Pump pressure Operating
Nominal at Tie-in Pipeline Pipeline Inlet Operating Pipeline HIPPS
Pipeline Pipeline ΔT Discharge as a % of pressure as a
Pipeline to Inlet pressure Temp at Design Set
Length (Winter velocity (°C) Pressure Mechanica % of HIPPS
Size Pressure drop Temp Tie-in Pressure Pressure
Case) l Design Set Pressure
Header
(Note 1) Pressure

NPS km kg/h m/s barg barg bar °C °C °C barg barg barg barg barg

8 3.4 102.3 22.3 37.6 2.4 105.2 112% 116%

10 9.90 224,898 2.2 80 86.8 6.8 40 37.0 3.0 89.7 94 95% 91 99%

12 1.5 82.7 2.7 36.8 3.2 85.6 91% 94%

Note 1: LPG Pump Discharge Pressure = Pipeline Inlet Pressure + In-plant Piping Loss (2.9 bar)

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Tables 5.15 to 5.16 below present the hydraulic results for the LPG export pipeline for winter LPG export flow (224,898 kg/h), at pipeline diameters of
8”, 10”, and 12”, API 5L X60 pipeline grade, at 40°C operating temperature.
Table 5-15: Case 5: Winter LPG Export Flow, 56°C operating temp, 28°C soil temp, API 5L X60
LPG Operating
Pressure
Flow Pump pressure Operating
Nominal at Tie-in Pipeline Pipeline Inlet Operating Pipeline HIPPS
Pipeline Pipeline ΔT Discharge as a % of pressure as a
Pipeline to Inlet pressure Temp at Design Set
Length (Winter velocity (°C) Pressure Mechanica % of HIPPS
Size Pressure drop Temp Tie-in Pressure Pressure
Case) l Design Set Pressure
Header
(Note 1) Pressure

NPS km kg/h m/s barg barg bar °C °C °C barg barg barg barg barg

8 3.5 103.0 23.0 53.1 2.9 105.9 113% 116%

10 9.90 224,898 2.3 80 87.1 7.1 56 52.7 3.3 90.0 94 96% 91 99%

12 1.6 82.8 2.8 52.4 3.6 85.7 91% 94%

Note 1: LPG Pump Discharge Pressure = Pipeline Inlet Pressure + In-plant Piping Loss (2.9 bar)

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Table 5-16: Case 6: Winter LPG Export Flow, 56°C operating temp, 15°C soil temp, API 5L X60
Operating
Pressure LPG
Flow pressure Operating
Nominal at Tie-in Pipeline Pipeline Inlet Operating Pump Pipeline HIPPS
Pipeline Pipeline ΔT as a % of pressure as a
Pipeline to Inlet pressure Temp at Discharge Design Set
Length (Winter velocity (°C) Mechanica % of HIPPS
Size Pressure drop Temp Tie-in Pressure Pressure Pressure
Case) l Design Set Pressure
Header (Note 1)
Pressure

NPS km kg/h m/s barg barg bar °C °C °C barg barg barg barg barg

8 3.5 103.0 23.0 51.7 4.4 105.9 113% 116%

10 9.90 224,898 2.3 80 87.1 7.1 56 51.1 4.9 90.0 94 96% 91 99%

12 1.6 82.8 2.8 50.8 5.3 85.7 91% 94%

Note 1: LPG Pump Discharge Pressure = Pipeline Inlet Pressure + In-plant Piping Loss (2.9 bar)

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5.15 Conclusion

The most conservative case for pipeline ∆P is maximum winter LPG export flow of 224,898
kg/h, and highest LPG operating temperature into the pipeline of 56C. LPG viscosity increases at
the lower operating temperature of 40°C. However although there is an increase in pressure drop
due to higher viscosity, this does not offset the increase in pressure drop due to a higher
volumetric flowrate (lower LPG density at 56°C). Refer to the summary in Table 5.17 below
which compares the pipeline ∆P results for all cases for API 5L X60 pipeline grade.

Table 5-17: Pipeline ∆P for hydraulic cases for API 5L X60 pipeline grade
Pipeline ∆P (bar)
Operating Soil
Pipeline LPG Flow
Case Temperature Temperature 10” 12”
Grade (kg/h) 8” pipeline
(°C) (°C) pipeline pipeline
diameter
diameter diameter

1 28 15.5 4.8 1.9


187138 40
2 15 15.5 4.7 1.9

3 28 22.3 6.9 2.7


X60 40
4 15 22.3 6.8 2.7
224898
5 28 23.0 7.1 2.8
56
6 15 23.0 7.1 2.8

Hence the selection of pipeline diameter and the following conclusions presented below are
based on the hydraulics for this case, and API 5L X60 pipeline grade wall thickness and ID.

8" pipeline diameter is not feasible because the LPG pump discharge pressure of 105.9 barg
exceeds the pipeline design pressure of 94 barg. There is no margin to allow the HIPPS to be set
to protect the pipeline from overpressure.

For 12” pipeline diameter, the maximum operating pressure at the LPG pump discharge is 85.7
barg, allowing 6% margin to the HIPPS set pressure at 91 barg. Alternatively, the HIPPS set
pressure could be lowered to 89 barg, which allows 5% margin from maximum operating
pressure to HIPPS set pressure, and 5% margin from HIPPS set pressure to pipeline design
pressure (refer to Table 5.18 below).

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Table 5-18: Pressure Margins – 12” LPG pipeline diameter


HIPPS Set Pressure HIPPS Set Pressure
at 91 barg at 89 barg
Parameter Description Parameter Difference Parameter Difference
Pipeline Design Pressure (barg) 94 - 94 -
HIPPS Set Pressure (barg) 91 3% 89 5%
Maximum Operating Pressure at
85.7 6% 85.7 4%
LPG Pump Outlet (barg)

For 10” pipeline diameter, the maximum operating pressure is 90 barg, and is too close to the
HIPPS set pressure of 91 barg (only 1% margin-refer to Table 5.19 below). There is insufficient
margin between maximum operating and HIPPS set pressure which could result in unnecessary
and frequent pipeline trips.

Table 5-19: Pressure Margins – 10” LPG pipeline diameter


Parameter Description Parameter Difference
Pipeline Design Pressure (barg) 94 -
HIPPS Set Pressure (barg) 91 3%
Maximum Operating Pressure at
90 1%
LPG Pump Outlet (barg)

A 12” diameter LPG pipeline is recommended, with HIPPS set pressure at 91 barg. The size
selection of 12” accommodates the maximum pressure drop case across the pipeline for winter
LPG export flow and maximum LPG operating temperature. The selection of 12” diameter for
the LPG pipeline is proposed and agreed in 8015-0152-WP05- L-00-PC-TQ-00082
[Ref.19].

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6. PRODUCED WATER PIPELINE

6.1 Process Description

Up until Year 2023, water is exported to CPF, and also supplied to water
injection. From Year 2024 to Year 2035, there is no excess produced water exported to
(as it is consumed by water injection only).
From the Treated Water Storage Tank (22-484-00-TK-002A/B) within CPF, the treated
water is pumped to CPF through the non-metallic GRE produced water export pipeline
via the Water Injection Pump (LP) (22-484-00-P-002A-D).
Within the CPF, the line is connected into the existing 42” piping transferring treated
water into the Storage Tank. As per Technical Query 8015-0152-WP05- L-00-PR-
TQ-00010 [Ref.11], the tie-in pressure (to accommodate tank static head) is 2 barg.

6.2 Flow Correlations

Schlumberger PIPESIM Version 2011.1 with Hazen Williams pressure drop correlation (for
single phase, water) is applied. C = 130 for carbon steel pipeline.

6.3 Fluid Composition

In PIPESIM, the compositional model is used with water as 100%.

6.4 Pipeline Design Flow

As referenced from 8015-0512-WP05-22-400-PC-HM-04001 Heat and Mass Balance for Water


Treatment Systems, the maximum excess produced water exported is 2430m3/h, which occurs in
Year 2021. The pipeline is designed for 2430m3/h plus 10% design margin (2673 m3/h). For
water density of 986 kg/m3 at 55°C, mass flow is 2,634,642 kg/h.

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6.5 Simulation Cases

A summary of the simulation cases for sizing of the produced water pipeline are provided below:

Table 6-1: Steady-State Hydraulic Cases


Parameter Description Parameter
18
20
Pipeline Diameter (NPS)
24
28
28 (summer)
Ambient soil temperature (°C)
15 (winter)
Pipeline Inlet Temperature (°C) 55

6.6 Pipeline Design Conditions

Pipeline mechanical design conditions for the non-metallic GRE produced water export pipeline
are as follows:

Table 6-2: Produced Water Pipeline Mechanical Design Conditions


Pipeline Pipeline Pipeline
Mechanical Mechanical Design
Design Pressure Temperature
barg °C
Produced Water Pipeline 32 70

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6.7 Pipeline Heat Transfer Parameters

Table 6-3 below provides details of the pipeline and soil characteristics. The hydraulic study is
based on GRE non-metallic pipeline.
Table 6-3: Pipeline & Soil Characteristics
Data Parameter
Pipeline Material GRE
Carbon Steel Roughness 0.0053 mm [Note 2]
Pipeline Thermal Conductivity 0.33 W/mK [Note 2]
Pipeline Burial Depth 1 m below ground from top of pipe [Note 1]
Soil Thermal Conductivity 1.12 W/mK
Soil Summer Temperature 28 °C
Soil Winter Temperature 15 °C
Wind Velocity 4 m/s
Note 1: In PIPESIM, pipeline is considered as fully buried 1m below ground from top of
pipeline.
Note 2: Properties of GRE are referenced from Ameron Product Data for Series 2400 Fiberglass
pipe.

6.8 Pipeline Diameter

The pipeline data based on non-metallic GRE pipeline is as follows:

Table 6-4: Produced Water Pipeline Data


Design Pressure = 32 barg, Design Temperature = 70°C
[Note 1]
Nominal Pipeline Wall Pipeline ID
Pipeline OD Thickness
Diameter (NPS) (mm) (mm)
(mm)
18 462.2 14.2 433.8
20 513.5 15.7 482.1
24 616.2 18.8 578.6
28 744.6 22.3 700
Note 1: Properties of GRE are referenced from Ameron Product
Data for Series 2400 Fiberglass pipe

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6.9 Pipeline Length

As per pipeline routing plan, the total pipeline length from the IPS to CPF is 11.03km.
Equivalent length applied is 1.05 of actual pipeline length to account for friction loss from
pipeline bends and fittings.

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6.10 Pipeline Elevation

Produced water pipeline elevation is shown in Figures 6.5 and 6.6 below.
Figure 6-5: Produced Water Pipeline Topography

CPF
Pipeline direction CPF

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Figure 6-6: Produced Water Pipeline Elevation

Produced Water Pipeline Elevation


6 Pipeline is buried 1m
below ground level

CPF
Pipeline direction
5
CPF

Elevation (m) 3
Ground
Level

Pipeline
2

0
Datum 0 1 2 3 4 5 6 7 8 9 10 11 12
Length (m)

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6.11 Battery Limit Conditions

The process operating conditions for the produced water pipeline inlet and outlet are summarized
below.

Table 6-7: Process Battery Limit Conditions


Parameter Description Parameter
Pipeline Inlet Temperature 55°C (max)
Calculated
Pipeline Inlet Pressure
(maximum of 22 barg)
Pipeline Outlet Pressure at 2 barg [Note 1]
Pipeline Outlet Temperature at Calculated
Note 1: 2 barg tie-in pressure at is referenced as per Technical Query 8015-0152-WP05-
L-00-PR-TQ-00010 [Ref.11]
Note 2: Maximum pressure at pipeline inlet based on available pump discharge pressure from LP
pump.

6.12 Results

The hydraulic results for the produced water pipeline are based on diameter of 18”, 20”, 24” and
28”.
Table 6-8: Produced Water Pipeline Hydraulics [winter soil temperature 15°C]
Nominal Pipeline Pipeline Pressure Pipeline Pipeline
Pipeline pressure pressure ΔP/100m
Flow velocity at IPS
Size drop at CPF
(NPS) kg/h m/s barg bar barg bar/100m
18 2,634,642 5.0 2 37.0 39.0 0.32
20 2,634,642 4.1 2 22.1 24.1 0.19
24 2,634,642 2.8 2 9.1 11.1 0.08
28 2,634,642 1.9 2 3.6 5.6 0.03

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Table 6-9: Produced Water Pipeline Hydraulics [summer soil temperature 28°C]
Nominal Pipeline Pipeline Pressure Pipeline Pipeline
Pipeline pressure pressure ΔP/100m
Flow velocity at IPS
Size drop at CPF
(NPS) kg/h m/s barg bar barg bar/100m
18 2,634,642 5.0 2 37.0 39.0 0.32
20 2,634,642 4.1 2 22.1 24.1 0.19
24 2,634,642 2.8 2 9.1 11.1 0.08
28 2,634,642 1.9 2 3.6 5.6 0.03

6.13 Conclusion

The Water Injection Pumps (LP) (22-484-00-P-002A-D) which supplies water injection to the
CPF water injection trunklines and the produced water pipeline has a discharge
pressure of 23.7 barg [Ref.12]. Allowing for piping pressure drop up to the fence line (1.7 bar),
the available pressure at the pipeline inlet is 22 barg. For the design flow, 24” pipeline diameter
results in a velocity of 2.8 m/s and with 9 bar pressure drop the pipeline inlet pressure is lower
than the available pump pressure. 24” pipeline diameter is selected for the produced water
pipeline.

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7. THIRD RIVER WATER PIPELINE

7.1 Process Description

The TRW transfer pipeline provides river water from the Third River Water Plant to both
CPF and CPF. As part of the scope of this project, the pipeline shall be
supplied from the IPS to the receipt point at CPF. Within the CPF, the TRW is
transferred to UF Filtered Water Tank 22-335-00-TK-002A/B in the CPF, from where
it supplies process needs to the facility. TRW will be a permanent supply to
CPF and provide process utility water demands for CPF only, while water injection
will be supplied by the CSSP sea water pipeline.

7.2 Flow Correlations

Schlumberger PIPESIM Version 2011.1 with Hazen Williams pressure drop correlation (for
single phase, water) is applied. C = 130 for carbon steel pipeline.

7.3 Fluid Composition

In PIPESIM, the compositional model is used with water as 100%.

7.4 Pipeline Design Flow

As referenced from Basis of Design 8015-0152-WP05-61-600-PC-BD-09001 [Ref 3], the peak


required TRW intake flow is 1587 m3/h. Hence the pipeline shall be sized for 1587m3/h plus
10% design margin. For water density of 999 kg/m3 at 12°C, mass flow is 1,744,653 kg/h.

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7.5 Cases

A summary of the simulation cases for sizing of the TRW pipeline section to CPF are
provided below:

Table 7-1: Steady-State Hydraulic Cases


Parameter Description Parameter
24
Pipeline Diameter (NPS) 28
30
28 (summer)
Ambient soil temperature (°C)
15 (winter)
Pipeline Inlet Temperature (°C) 12 [Note 1]
Note 1: Minimum and maximum temperature of the treated water at the source is 12 °C and 34
°C respectively. Minimum temperature is considered for pipeline sizing due to higher pressure
drop (maximum water viscosity).

7.6 Pipeline Design Conditions

As defined in 8015-0150-WP01-31-750-PC-RP-00002 TRW Steady-state Hydraulics Report


[Ref.7], the TRW pipeline design pressure of 46 barg is selected based on maximum of pump
shut-off pressure, surge pressure under river water service and 110% of operating pressure
during seawater service.

Table 7-2: TRW Pipeline Mechanical Design Conditions


Pipeline Pipeline Pipeline
Mechanical Mechanical Design
Design Pressure Temperature
barg °C
Third River Water Pipeline 46 50

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7.7 Pipeline Heat Transfer Parameters

Table 7-3 below provides details of the pipeline and soil characteristics. The hydraulic study is
based on Carbon steel pipeline with 3 mm corrosion allowance.
Table 7-3: Pipeline & Soil Characteristics
Data Parameter
Pipeline Material Carbon Steel
Carbon Steel Roughness 0.046 mm
Pipeline Thermal Conductivity 45 W/mK
Pipeline Burial Depth 1 m below ground from top of pipe [Note 2]
Soil Thermal Conductivity 1.12 W/mK
Soil Summer Temperature 28 °C
Soil Winter Temperature 15 °C
Pipeline Coating 3 Layer Polyethylene (3LPE)
Pipeline Thickness 3mm
Pipeline Coating Thermal Conductivity 0.414 W/mK
Wind Velocity 4 m/s
Note 1: Based on pipeline routing plan concrete coating is applicable for sections through wet
land area. For the purposes of hydraulic analysis, concrete coating has not been considered.
Note 2: In PIPESIM, pipeline is considered as fully buried 1m below ground from top of
pipeline.

7.8 Pipeline Diameter

The pipeline data based on API 5L X60 pipe grade and 3mm corrosion allowance is as follows:
Table 7-4: Pipeline Data for API 5L X60 [Note 1]
Design Pressure = 46 barg, Design Temperature = 50°C
API 5L X60, CA 3 mm
Nominal Pipeline Wall Pipeline ID
Pipeline OD Thickness (mm)
Diameter (NPS) (mm) (mm)

24 609.6 11.1 587.3


28 711.2 11.9 687.4
30 762.0 12.7 736.6
Note 1: The above WT and ID data has been considered for the purposes of hydraulics.
Final WT and ID data is based on location class across the pipeline route.

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7.9 Pipeline Length

As per pipeline routing plan, the total pipeline length from the IPS to CPF is 10 km.
Equivalent applied is 1.05 of actual pipeline length to account for friction loss from pipeline
bends and fittings.

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7.10 Pipeline Elevation

TRW pipeline elevation is shown in Figures 7.5 and 7.6 below.


Figure 7-5: TRW Pipeline Topography

IPS
Pipeline direction CPF

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Figure 7-6: TRW Pipeline Elevation

4.5
TRW Pipeline Elevation Pipeline is buried 1m
below ground level

4
Pipeline direction

3.5

2.5
Elevation(m)
Ground Level
2 Pipeline

1.5

0.5

Datum 0
0 2 4 6 8 10 12
Distance(Km)

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7.11 Battery Limit Conditions

The tie-in pressure from the TRW pipeline is referenced from TRW Steady-state Hydraulics
Report 8015-0150-WP01-31-750-PC-RP-00002 for Case 3, which considers pressure drop
across the 40” main TRW pipeline at 770 skbpd flow rate (supply to both and
CPF).

The TRW is transferred to UF Filtered Water Tank (22-335-00-TK-002A/B) in the


CPF. To allow for maximum tank head and piping losses from the fence line to the tank, the
minimum arrival pressure required is considered as 2.5barg.

The process operating conditions for the TRW pipeline inlet and outlet are summarized below.

Table 7-7: TRW Pipeline Mechanical Design Conditions


Parameter Description Parameter
Pipeline Inlet Temperature at IPS 12°C (min) / 34°C (max)
Pipeline Inlet Pressure at IPS 5 barg [Note 1]
Calculated
Pipeline Outlet Pressure at CPF
(minimum of 2.5 barg)
Pipeline Outlet Temperature at IPS Calculated
Note 1: Referenced from 8015-0150-WP01-31-750-PC-RP-00002 TRW Steady-state Hydraulics
Report [Ref.7]

7.12 Results

The hydraulic results for the TRW pipeline based on diameter of 24”, 28”, and 30” and API 5L
X60 pipeline grade are summarized below.
Table 7-8: Hydraulic results (winter soil temperature 15°C, API 5L X60)
Nominal Pipeline Pipeline Pipeline
Pipeline Pipeline Pressure ΔT
Pipeline pressure pressure ΔP/100m
Flow velocity at IPS
Size drop at CPF [Note1]
(NPS) kg/h m/s barg bar barg bar/100m °C
24 1.8 4.4 0.6 0.04 0.14
28 1,744,653 1.3 5 1.9 3.1 0.02 0.09
30 1.1 1.3 3.7 0.01 0.08
Note 1: As ambient soil temperature (15°C) is greater than water temperature (12°C), water is
heated.

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Table 7-9: Hydraulic results (summer soil temperature 28°C, API 5L X60)
Nominal Pipeline Pipeline Pressure Pipeline Pipeline Pipeline
Pipeline pressure pressure ΔP/100m ΔT
Flow velocity at IPS
Size drop at CPF [Note1]
(NPS) kg/h m/s barg bar barg bar/100m °C
24 1.8 4.4 0.6 0.04 0.32
28 1,744,653 1.3 5 1.9 3.1 0.02 0.28
30 1.1 1.3 3.7 0.01 0.28
Note 1: As ambient soil temperature (15°C) is greater than water temperature (12°C), water is
heated.

7.13 Conclusion

With a 24” diameter pipeline, arrival pressure at the UF Filtered water tank is too low (0.6 barg),
and hence selection of 24” pipeline is not feasible. A 28” pipeline diameter with 2 bar pressure
drop across the pipeline is recommended. The arrival pressure at the CPF meets the minimum
requirement of 2.5 barg.

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8. CSSP SEAWATER PIPELINE

8.1 Process Description

The Sea Water Pipeline provides sea water from the Central Sea Water Supply Project (CSSP)
pipeline to both CPF and CPF. The CSSP sea water import pipeline to
CPF is sized for both water injection and process water demands in the event that TRW
supply is lost, and is routed to the UF Feed Tank (22-335-00-TK-001A/B) in the Raw Water
Treatment Package.

8.2 Flow Correlations

Schlumberger PIPESIM Version 2011.1 with Hazen Williams pressure drop correlation (for
single phase, water) is applied. C = 130 for carbon steel pipeline.

8.3 Fluid Composition

In PIPESIM, the compositional model is used with water as 100%.

8.4 Pipeline Design Flow

As referenced from Basis of Design 8015-0152-WP05-61-600-PC-BD-09001 [Ref.3], the peak


required CSSP seawater intake flow is 6172 m3/h. Hence the pipeline shall be sized for
6172m3/h plus 10% design margin (6789 m3/h). For water density of 999 kg/m3 at 12°C, mass
flow is 6,789,200 kg/h.

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8.5 Cases

A summary of the simulation cases for sizing of the CSSP seawater pipeline section to
CPF are provided below. As sweater water operating temperature is not available [HOLD-1],
12°C (same as for TRW supply) has been assumed.
Table 8-1: Steady-State Hydraulic Cases
Piping / Equipment Parameter
30
32
Pipeline Diameter (NPS)
36
40
28 (summer)
Ambient soil temperature (°C)
15 (winter)
Pipeline Inlet Temperature (°C) 12 [HOLD-1]

8.6 Pipeline Design Conditions

As specified in CSSP Design Basis MOM 8015-0152-WP05- L-00-AL-MM-00166


[Ref.13], the CSSP pipeline design pressure is 90 barg. As the CSSP pipeline mechanical design
temperature is not available [HOLD-2], 50°C mechanical design temperature for the purposes of
the wall thickness calculation has been assumed.

Table 8-2: CSSP Seawater Pipeline Mechanical Design Conditions


Pipeline Pipeline Pipeline
Mechanical Mechanical Design
Design Pressure Temperature
barg °C
CSSP Seawater Pipeline 90 50 [HOLD-2]

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8.7 Pipeline Heat Transfer Parameters

Table 8.3 below provides details of the pipeline and soil characteristics. The hydraulic study is
based on Carbon steel pipeline with 6 mm corrosion allowance.
Table 8-3: Pipeline & Soil Characteristics
Data Parameter
Pipeline Material Carbon Steel
Carbon Steel Roughness 0.046 mm
Pipeline Thermal Conductivity 45 W/mK
Pipeline Burial Depth 1 m below ground from top of pipe [Note 2]
Soil Thermal Conductivity 1.12 W/mK
Soil Summer Temperature 28 °C
Soil Winter Temperature 15 °C
Pipeline Coating 3 Layer Polyethylene (3LPE)
Pipeline Thickness 3mm
Pipeline Coating Thermal Conductivity 0.414 W/mK
Wind Velocity 4 m/s
Note 1: Based on pipeline routing plan concrete coating is applicable for sections through wet
land area. For the purposes of hydraulic analysis, concrete coating has not been considered.
Note 2: In PIPESIM, pipeline is considered as fully buried 1m below ground from top of
pipeline.

8.8 Pipeline Diameter

The pipeline data based on API 5L X60 pipe grade and 6mm corrosion allowance is as follows:
Table 8-4: CSSP Seawater Pipeline Data for API 5L X60
Design Pressure = 90 barg, Design Temperature = 50°C
API 5L X60, CA 6 mm
Nominal Pipeline Wall Pipeline ID
Pipeline OD Thickness (mm)
Diameter (NPS) (mm) (mm)

30 762 19.1 723.8


32 812.8 19.1 774.6
36 914.4 20.6 873.2
40 1016 22.2 971.6
Note 1: The above WT and ID data has been considered for the purposes of hydraulics.
Final WT and ID data is based on location class across the pipeline route.

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8.9 Pipeline Length

As per pipeline routing plan, the total pipeline length from the IPS to CPF is 10.2km.
Equivalent applied is 1.05 of actual pipeline length to account for friction loss from pipeline
bends and fittings.

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8.10 Pipeline Elevation

CSSP pipeline elevation is shown in Figures 8.5 and 8.6 below.


Figure 8-5: CSSP Pipeline Elevation

CPF Pipeline direction ICS

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Figure 8-6: CSSP Pipeline Elevation

CSSP Seawater Pipeline Elevation


6
Pipeline is buried 1m
below ground level

5
ICS

4
CPF

Elevation (m) 3
Ground Level
Pipeline

Datum 0
0 1 2 3 4 5 6 7 8 9 10 11
Pipeline Length (m)

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8.11 Battery Limit Conditions

The process operating conditions for the CSSP pipeline inlet and outlet are summarized below.

Table 8-7: CSSP Pipeline Mechanical Design Conditions


Parameter Description Parameter
12°C (min) / 34°C (max)
Pipeline Inlet Temperature at ICS
[Note 1]
Pipeline Inlet Pressure at ICS Calculated
Pipeline Outlet Pressure at CPF 2 barg
Pipeline Outlet Temperature at CPF Calculated
Note 1: As data in not available [HOLD-1], operating temperature for CSSP seawater is assumed
(same as for TRW)

8.12 Results

The hydraulic results for the CSSP pipeline based on diameter of 30”, 32”, 36”, 40” and 42” and
API 5L X60 are summarized below.
Table 8-8: Hydraulic results [winter soil temperature 15°C, API 5L X60]
Nominal Pipeline Pipeline Pipeline
Mass Pipeline Pressure ΔP/
Pipeline pressure pressure ΔT
Flowrate velocity at ICS 100m
Size at CPF drop [Note 1]
(NPS) kg/h m/s barg barg bar bar / m °C
30 4.58 2 23.0 21.0 0.20 0.5
32 4.00 2 17.1 15.1 0.14 0.3
6,789,200
36 3.15 2 10.4 8.4 0.08 0.2
40 2.54 2 7.0 5.0 0.05 0.1
Note 1: As ambient soil temperature (15°C) is greater than water temperature (12°C), water is
heated.

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Table 8-9: Hydraulic results [summer soil temperature 28°C, API 5L X60]
Nominal Pipeline Pipeline Pipeline
Mass Pipeline Pressure ΔP/
Pipeline pressure pressure ΔT
Flowrate velocity at ICS 100m
Size at CPF drop [Note 1]
(NPS) kg/h m/s barg barg bar bar / m °C
30 4.58 2 23.0 21.0 0.20 0.5
32 4.00 2 17.1 15.1 0.14 0.4
6,789,200
36 3.15 2 10.4 8.4 0.08 0.3
40 2.54 2 7.0 5.0 0.05 0.2
Note 1: As ambient soil temperature (28°C) is greater than water temperature (12°C), water is
heated.

8.13 Conclusion

For 32” pipeline diameter with API 5L X60 pipeline grade, the calculated backpressure at the
ICS based on 2 barg arrival pressure at the CPF is 17.1 barg, and the liquid velocity is 4
m/s. 30” pipeline diameter is not recommended as the velocity would be too high. With WT for
API 5L X60 pipeline grade, 32” pipeline diameter for the pipeline section from ICS to
CPF is selected, provided that 17.1 barg pressure is available at the ICS tie-in to the CSSP
seawater pipeline, which L are to confirm [HOLD-3].

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9. SUMMARY

The selected pipeline diameters are summarized below:


Table 9-1: Pipeline Sizing Summary
Pipeline Sizing Summary
Mechanical Mechanical
Nominal Pipeline Wall
Design Design Pipeline ID
Pipeline OD Thickness
Pipeline Pressure Temperature (mm)
Diameter (mm) (mm)
(barg) (°C) [Note 1,2]
(NPS) [Note 1,2]

Crude Oil 40 47 70 1016 11.13 993.7


Sales Gas 28 94 85 711.2 15.9 679.4
LPG 12 94 85 323.9 8.4 307.1
Third
River 28 46 50 711.2 11.9 687.4
Water
Produced
24 32 70 616.2 18.8 578.6
Water
CSSP
50
Sea 32 90 812.8 19.1 774.6
Water [HOLD-2]
Note 1: The ID and WT for all carbon steel pipelines (Crude Oil, Sales Gas, LPG, TRW and
CSSP sea water) are based on API 5L X60 pipeline grade [Ref.17].
Note 2: The above WT and ID data has been considered for the purposes of hydraulics.
Final WT and ID data is based on location class across the pipeline route.

The available pressure at the ICS (where CSSP seawater pipeline connects into the
main CSSP seawater pipeline) is dependent on the characteristics of the CSSP supply pump
curves and pressure drop and hydraulics in the upstream system (which is dependent on the
demand of seawater users upstream of and ). This information is currently not
available at the time of completion of the Export Steady State Report for the FEED
Project [HOLD-3]. Once this data becomes available during the Detailed Design Engineering
Phase, the line size of the CSSP seawater pipeline should be re-reviewed on this basis.

For all pipelines included in this report, final hydraulics to be re-visited in Detailed Design
Engineering Phase based on final pipeline alignment sheets, final CPF plant piping isometrics,
and fiscal metering pressure drop data specified by the vendor [HOLD 4, 5 &6].

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10. Appendix 1 – Crude Oil Composition


Refer to Basis of Design 8015-0152-WP05-12-000-PC-BD-04001 for Pseudo Component
Properties
Component Mole % Component Mole %
Hydrogen Sulphide 0.00% NBP[0]337* 2.16%
Carbon Dioxide 0.00% NBP[0]351* 2.04%
Nitrogen 0.00% NBP[0]365* 1.91%
Methane 0.00% NBP[0]379* 1.80%
Ethane 0.00% NBP[0]392* 1.70%
Propane 0.08% NBP[0]406* 1.68%
Isobutane 0.28% NBP[0]420* 1.58%
Butane 2.20% NBP[0]440* 2.59%
Isopentane 1.77% NBP[0]468* 1.74%
Pentane 2.40% NBP[0]496* 1.54%
Hexane 1.62% NBP[0]521* 1.43%
Heptane 0.55% NBP[0]552* 3.37%
Octane 0.13% TOTAL: 100.00%
NBP[0]5* 1.74%
NBP[0]19* 3.25%
NBP[0]33* 3.44%
NBP[0]46* 3.22%
NBP[0]60* 2.94%
NBP[0]74* 2.71%
NBP[0]88* 2.43%
NBP[0]102* 2.12%
NBP[0]116* 1.91%
NBP[0]129* 2.11%
NBP[0]143* 2.28%
NBP[0]157* 4.25%
NBP[0]171* 4.50%
NBP[0]185* 3.62%
NBP[0]199* 3.42%
NBP[0]213* 3.12%
NBP[0]226* 2.84%
NBP[0]240* 2.68%
NBP[0]254* 2.57%
NBP[0]268* 2.58%
NBP[0]282* 2.57%
NBP[0]296* 2.49%
NBP[0]309* 2.39%
NBP[0]323* 2.27%

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11. Appendix 2 – Sales Gas Composition


Refer to Basis of Design 8015-0152-WP05-12-000-PC-BD-04001 for Pseudo Component
Properties
Component Mole %
Hydrogen Sulphide 0.00%
Carbon Dioxide 0.05%
Nitrogen 0.55%
Methane 74.63%
Ethane 19.38%
Propane 4.38%
Isobutane 0.25%
Butane 0.48%
Isopentane 0.01%
Pentane 0.01%
Hexane 0.00%
Heptane 0.00%
Octane 0.00%
H20 0.00%
NBP[0]5* 0.18%
NBP[0]19* 0.06%
NBP[0]32* 0.01%
NBP[0]46* 0.00%
TOTAL: 100.00%

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12. Appendix 3 – LPG Composition


Refer to Basis of Design 8015-0152-WP05-12-000-PC-BD-04001 for Pseudo Component
Properties
Component Mole %
Hydrogen Sulphide 0.00%
Carbon Dioxide 0.00%
Nitrogen 0.00%
Methane 0.00%
Ethane 0.10%
Propane 49.00%
Isobutane 10.17%
Butane 28.20%
Isopentane 0.14%
Pentane 0.03%
Hexane 0.00%
Heptane 0.00%
Octane 0.00%
NBP[0]5* 10.60%
NBP[0]19* 1.67%
NBP[0]32* 0.09%
TOTAL: 100.00%

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