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7. MANUFACTURING
7.1. Mother Pipe
Mother pipe shall be manufactured as within the requirements as stated in the DEP
31.40.20.37 Ref. [8] and line pipe specifications report. The carbon steel shall be
ISO 3183 Ref [22] PSL 2.
Company shall be notified if there is intent to upgrade or modify the strength of
either the mother pipe or induction bend after the bending process.
7.2. Qualification Test Bend
The test bends shall be manufactured with approved MPS as stated in the DEP
31.40.20.33 Gen. Ref. [6]
7.3. Production Bending
Induction bending shall be carried out in accordance with the qualified MPS.
Interruption of the induction bending operation shall result in rejection of the
bend.
7.4. Post-Bending Heat Treatment
Except acceptable properties can be demonstrated after bending for any L450 X65
line, the
Contractor shall provide a quench and temper heat treatment of the entire joint.
The temperature of each furnace-load of bends shall be monitored by thermocouples
connected directly to selected bends and shall be recorded. The type and location
of the thermocouples shall be as specified in the MPS.
7.5. Strip/Plate End Welds
Induction bends shall not contain coil-strip end welds or plate end welds.
7.6. Forming and Sizing after Bending
This shall be done according to ISO 15590-1 Ref [20] as amended by DEP 31.40.20.33-
Gen. Ref. [6]
7.7. Jointers and Girth Welds
Induction bends ordinarily should not contain girth welds. The DEP 31.40.20.33-Gen
Ref. [6] permits jointers during manufacture of bends on the condition that on
completion of the bend, the joiner shall be removed such that no effect from the
joiner shall remain including the heat affected zone.
7.8. End Preparation
Bends shall be square except otherwise specified by company. The cutting method
shall not affect the properties of the bend when compared to the mother pipe.
The sleeves shall be provided in sheet form which can be wrapped around the pipe
and closed to form
a tube which shall upon the application of heat, shrink around the joint.
The type of field joint coating selected for this project is Polyethylene Heat
Shrinkable Sleeves and the
Polyethylene Heat Shrinkable Sleeves shall be applied over a suitable epoxy primer
coating in
accordance to section 8.1.4.2 of DEP 31.40.30.37.
The external surfaces of joints and bends shall be coated as follows:
The pipeline field joints shall be coated with Polyethylene Shrink Sleeves.
The bends, elbows and other irregular configurations on pipelines shall be coated
with heat
Shrinkable Cross-linked Polyolefin Tape.
The minimum acceptable standard of surface preparation shall be to the following
equivalent
internationally recognized standards.
ISO 8501-1
Sa 2½ Near white SSPC-SP10
On completion, the entire surface shall show the blast cleaning pattern and at
least 95% of the surface
shall be clean, bare steel. The surface may show some shadows, streaks or
discoloration, but these
should be slight and distributed over the surface, and not concentrated in spots or
areas.
3.2. Information to be Supplied by the Contractor
For this project qualification, the CONTRACTOR shall supply technical information
to the
SUPPLIER regarding the project, in particular the installation and operating
conditions. This
information shall contain as a minimum in accordance to DEP 31.40.30.37-Gen Section
6.1Abrasive Blast Cleaning shall be in accordance with DEP 31.40.30.37-Gen, Section
9.2.1 through 9.2.6.
There are situations in which are economically advantageous to transport both
liquid and gas in a single pipeline simultaneosly .This is called Two phase flow
pipeline.
The Contractor shall notify the Company of any conflict between this specification,
the Codes and Standards and any other specification included as part of the Project
documen-tation.
This specification and the guidelines set forth do not relieve the Contractor, its
Sub- Con-tractors and Vendors of the responsibility to provide a finished product
capable of perform-ing its intended service.
Any exception to this specification and referenced documentation shall be raised by
the Contractor and approved by the Company in writing, following the applicable
procedure for concession requests as defined in the Quality Management Procedures
of the Project.
During further stages of the project (detailed design) Contractor is obliged to
verify calcula-tions, the design and dimensions of all equipment using its own
calculations based on pro-cess, design, safety and warranty data given in the
tender documentation. The detailed de-sign must be agreed upon with the Company.
i. The Contractor shall be responsible for the design and construction of all
aspects of the HDD works including any temporary works and temporary supporting
structures. All de-sign assumptions regarding subsurface conditions, equipment
requirements, groundwater and other factors are the responsibility of the
Contractor and shall be fully documented.
ii. Based on the alignment shown in the Principal Drawings, the Contractor shall
design and size the excavated profile to accommodate all temporary and permanent
works.
iii. A design vertical and horizontal profile shall be submitted to the
Superintendent’s
Representative for review prior to commencement of work.
iv. The Contractor shall not proceed with any work until the Contractor’s RPE
certified design has been accepted by the Superintendent’s Representative.
Acceptance of the Contrac-tor’s design by the Superintendent’s Representative in no
way diminishes the responsibility of the Contractor for the design.
v. The HDD crossing shall be designed in accordance with this Specification and
the refer-enced documents by a person suitably qualified and having experience with
the design considerations required for this type of work. The profile design shall
take into account the following:
• Temporary works associated with the HDD construction;
At least one (1) reading per drill rod is required during the drilling of the pilot
hole, registering inclination, heading, length, depth and the orientation of the
bent sub. This information shall be recorded on the steering log and be available
for inspection of the superintendent as and when required.
7.7.2.3 The Contractor shall ensure proper calibration of all equipment before
commencing directional drilling operation and provide proof of calibration
documentation to the Superintendent’s Representative
For steel piping operating above –20F, alloy steel studs ASTM
A193 Grade B7, with ASTM A194 Class 2H semi-finished heavy
hex nuts shall be used except for sulphide stress cracking service
where stud bolts shall be ASTM A193 Grade B7M. For steel piping
operating below –20F, ie: blowdown service, ASTM A320, Gr L7
studs, with ASTM A194, Gr 7 semi-finished hex nuts shall be used,
except for sulfide stress cracking services where stud bolts shall be
ASTM A320, Gr L7M.
For steel piping operating above –20F, alloy steel studs ASTM
A193 Grade B7, with ASTM A194 Class 2H semi-finished heavy
hex nuts shall be used except for sulphide stress cracking service
where stud bolts shall be ASTM A193 Grade B7M. For steel piping
operating below –20F, ie: blowdown service, ASTM A320, Gr L7
studs, with ASTM A194, Gr 7 semi-finished hex nuts shall be used,
except for sulfide stress cracking services where stud bolts shall be
ASTM A320, Gr L7M.
(2) Bolting threads and lengths shall conform to the dimensions listed
in the appropriate national or industry flange standard. Headed
bolts (rather than stud bolts) shall not be used without prior PTT
approval.
(3) All bolts and nuts shall be coated with PTFE, or equivalent
material.
(4) For Austenitic bolting materials shall be in accordance with piping
material classification data sheets.
1.4.6 Proprietary Connectors
Proprietary connectors shall be used as required by project Specifications.
1.5 Design Considerations for Particular Piping Systems
1.5.1 General
This
(2) Bolting threads and lengths shall conform to the dimensions listed
in the appropriate national or industry flange standard. Headed
bolts (rather than stud bolts) shall not be used without prior PTT
approval.
(3) All bolts and nuts shall be coated with PTFE, or equivalent
material.
(4) For Austenitic bolting materials shall be in accordance with piping
material classification data sheets.
1.4.6 Proprietary Connectors
Proprietary connectors shall be used as required by project Specifications.
1.5 Design Considerations for Particular Piping Systems
1.5.1 General
This
The finish required by B16.5 for steel raised-face flanges is also to
be used for non-steel metallic flanges, for steel male and female
flanges, that is 125 to 250 micro inches. For steel tongue and
grove flanges gasket face finish shall be 32-63 micro inches.
(5) For NPS 26” and larger, ASME B16.47 SERIES A flanges shall be
used. Use SERIES B flanges only when needed to mate with
equipment flanges. When attached to pipe with a yield strength
greater than 248.4 MPa (36000 psi), the hub thickness requires
prior PTT approval.
(6) Except for galvanized piping threaded flanges shall not be used
without prior PTT approval and then only in steel NPS 2 and
smaller.
(7) The bore of weld neck flanges to be used in severe cyclic
conditions, ie: reciprocating pumps and compressors, or in services
with high corrosion rates shall have the same ID as the attached
piping. If the ID is not the same, the flange shall be taper bored
conditions may bear on the abandonment decision-making process.
The development and implementation of an abandonment plan consists of at least the
following seven steps:
(1) review prevailing regulatory requirements applicable to the abandonment
project; (2) compile all relevant information on the pipeline system, including
easement agreements; (3) analyze by segment taking into account the factors
addressed in Section 3 of this paper, including present and future land use; (4)
develop the abandonment plan in consultation with stakeholders (such as landowners,
government authorities, and other directly affected parties), incorporating the
information compiled in the above steps; (5) secure regulatory and landowner
approvals as required for the pipeline abandonment and site reclamation; (6)
implement the abandonment plan, the scope of which should include post-abandonment
responsibilities (addressed in Section 4); and (7) secure final regulatory release.
The SDV valve will be provided at the station inlet and outlet. In case of an
emergency event the SDV valves will cut off the gas supply from the suppliers and
to the pipelines.
The compressor station will be designed for locally manned, fully automatic,
permanent operation from Station Control Room with remote monitoring of the station
from the Central Control Room.
9.2 Pig Receiver
Pig Receivers will be provided at all pipelines entering the compressor station.
The pig receiver is described in section 10.8.
9.3 Filter Separator Skid
The filter separators, as described in section 10.1, shall be provided at Obigbo
Compressor Station at each gas supply source.
The filter separator design and operating conditions are: Parameter Value QIT
Source Obigbo Node Source Cawthorne and Alakiri Source Okono/Okpoho
Design Pressure
98.0 barg
98.0 barg
98.0 barg
98.0 barg
Design Temperature
60˚C
60˚C
60˚C
60˚C
Operating Capacity
290 MMscfd
161 MMscfd
145 MMscfd
100 MMscfd
Maximum pressure drop clean
0.5 bar
0.5 bar
0.5 bar
0.5 bar
Maximum pressure drop dirty
1.0 bar
1.0 bar
1.0 bar
1.0 bar
Table 46 Filter Separators Design Conditions-Obigbo CS
Trans Nigeria Gas Pipeline Project (Early Gas Phase + Phase1) G791-ILF-XXGE-GE-REP-
0002 Rev. 3
BASIS OF DESIGN 06.05.2015
I L F C O N S U L T I N G E N G I N E E R S P a g e 97 of 181
ILF https://intern.project2.ilf.com/muc1/G791/TEAM/System Engineering/Basis of
Design/APV/G791-ILF-XXGE-GE-REP-0002_3_APV_BoD.docx © ILF 2015
9.4 Inlet Gas Metering and Control Package
The Gas Metering and Control Package, as described in section 10.4, shall be
designed to provide technical metering of gas transferred between the gas suppliers
and Obigbo Compressor Station, to equalize the gas arrival pressure supplied from
different sources and to maintain constant gas supply to the CS suction header.
The gas metering and control skid design conditions are: Parameter Value QIT Source
Obigbo Node Source Cawthorne and Alakiri Source Okono/Okpoho
Design Pressure
98 barg
98 barg
98 barg
98 barg
Design Temperature
60˚C
60˚C
60˚C
60˚C
Minimum outlet pressure
52 barg
52 barg
52 barg
52 barg
Operating Capacity
290 MMscfd
170 MMscfd
145 MMscfd
100 MMscfd
Table 47 Inlet Gas Metering and Control Skid Design Conditions-Obigbo CS
9.5 Turbo Compressors
For compression of gas, centrifugal compressors compliant to API 617 shall be
installed. The compressor shall preferably be driven by a gas turbine compliant
with API 616.
Gas flow from the station inlet towards the exit shall be ensured by an optimized
numbers of compressor units as resulting from the hydraulic simulations. TUCO units
selection shall be based on the “worst case” principle. The available gas turbine
power shall match the required total compressor shaft power under the most severe
ambient conditions (temperature, humidity, atmospheric pressure). The configuration
of the TUCO units for compressor station shall be the result of a study considering
the operational requirements and the availability of the overall system.
The TUCO units will be housed inside a common shed.
A unit control system (UCS) shall control each TUCO unit. Overall operation and
control of the complete CS will be provided by a station control system (SCS). The
SCS shall have a separate functionality for load sharing and station recycle for
overall control of all TUCO units within each station.
Trans Nigeria Gas Pipeline Project (Early Gas Phase + Phase1) G791-ILF-XXGE-GE-REP-
0002 Rev. 3
BASIS OF DESIGN 06.05.2015
I L F C O N S U L T I N G E N G I N E E R S P a g e 98 of 181
ILF https://intern.project2.ilf.com/muc1/G791/TEAM/System Engineering/Basis of
Design/APV/G791-ILF-XXGE-GE-REP-0002_3_APV_BoD.docx © ILF 2015
TUCO unit shall be delivered as a package. The TUCO unit package
A station recycle valve will be located between the discharge and suction header in
order to provide the following functions:
Establish the required compressor minimum flow in case of major sudden demand
reductions in the system (e.g. shut-down of any of gas off-takes);
allow for TUCO units load sharing in case of gas demand increase and reduction;
protect TUCO units against surge conditions as the first-stage protection;
Discharge gas from the TUCO Packages will flow to the air-coolers. The discharge
gas temperature downstream of the coolers will be controlled via variable speed
motors. Then the gas will be sent via the discharge header to the Outlet Gas
Metering Packages and the outlet control valves. Finally it will be routed to Ob/Ob
and/or Umuahia.
The outlet flow control valves will provide the following functions:
flow control and flow distribution in case of simultaneous gas supply in the
direction of Ob/Ob and Ajaokuta via Umuahia;
flow control in case of the Compressor Station by-pass operation;
pigging operation (gas flow control);
controlled pressurization of the outlet pipelines;
The outlet gas metering packages will provide technical metering of gas transferred
between the compressor station and TNGP pipelines and will transmit the TNGP system
boundary conditions data (actual pressure and flow) to the SCADA and Pipeline Leak
Detection