Vous êtes sur la page 1sur 188

GAS RETICULATION

SYSTEM
Assoc. Prof. Engr. Dr. Rahmat Bin Mohsin
Mohd. Dinie Muhaimin Samsudin
Storage and Reticulation System
SKN 4223
2
TYPE OF GAS PIPELINE SYSTEMS
Transmission

Is a line installed for the purposed of transmitting gas
from a source or sources of supply to one or more
distribution centers or a pipe installed to
interconnected sources or supply.
Transmission lines differ from gas distribution line in
that they operate at higher pressure, are longer and
have greater distance between connection
Storage and Reticulation System
SKN 4223
3
Distribution

Is a network of pipeline connecting the gas
from supply sources to the consumer
premises.
Supply source are transmission line for
natural gas and bulk storage for liquefied
petroleum gas.

Storage and Reticulation System
SKN 4223
4
Storage and Reticulation System
SKN 4223
5
Storage and Reticulation System
SKN 4223
6
GAS PIPE DESIGN COMPONENTS
1. Pipeline optimization
2. Selection and analysis of pipeline route
3. Geotechnical and environmental aspects
4. Engineering survey
5. Route design
6. Buoyancy control
7. Selection of materials
8. Stress analysis
9. Facility design
10. Corrosion control
Storage and Reticulation System
SKN 4223
7
Basic Concepts of Gas
Distribution System (Gas Supply)
Items to ensure stability of supply
High reliability
Low installation cost
Low maintenance
Materials and parts supply facilities
Supply system is determined based on the serviced
area, volume of gas needed, the capacity of existing
equipment, the possibility of the expansion,
maintenance and control facilities and costs.
Storage and Reticulation System
SKN 4223
8
In making the classification of consumers and
supply system, it is necessary to ensure the system is
safe and secure.
Supply system is classified to:
1. Large industry -> 1000 cubic meters per hour
2. Medium and small industries
3. Commercial
4. Domestic - <1 cubic meter per hour
Storage and Reticulation System
SKN 4223
9
Government Acts
Systems should be designed to comply with the requirements
of the following acts:
Petroleum Act (Safety Measures) 1984
Cover security measures to be considered in designing and
installation of gas and petroleum-related facilities.
Environmental Quality Act (1974)
Act governing the activities that may affect the environment.
Identify the mandatory environmental impact study
Factories and Machinery Act (1967)
To enforce the requirements of the tests carried out on a
high-pressure gas pipe installation, including welding
procedures, welder qualifications and other related.
Storage and Reticulation System
SKN 4223
10
Code of Practice and Standards
AGA : American Gas Association
ANSI : American National Standard Institute
ASME : American Society of Mechanical Testing
ASTM : American Society of Testing of Material
API : American Petroleum Institute
BS : British Standard
CSA : Canadian Standard Association
IP : Institute of Petroleum
ISA : Instrumentations Standards Association
MS : Malaysian Standard
MSS : Material Specification Standards
NACE : National Association of Corrosion Engineers
NEMA : National Electrical Manufacturing Association
PTS : Petronas Technical Standard
SIS : Standard Institution of Sweeden
SSPC : Steel Structure Painting Council
Storage and Reticulation System
SKN 4223
11
Design Factor and Class Location
The thickness of the pipe is determined by design
factors as contained in ANSI / ASME B31.8.
Class location is determined by calculating the density
of homes along the pipe to 200 m wide on the left and
right pipe during 1600 m.
Less than 10 houses Class I
10 to 40 houses Class II
More than 40 houses Class III
Storey building Class IV
Storage and Reticulation System
SKN 4223
12
DISTRIBUTION SYSTEM PIPELINE
Using steel and plastic pipeline with pipe diameter
and pressure lower than the transmission pipeline
system.
Consists of series of pipes that operate at
different pressures and there is no agreement or a
general statement or terminology on pressure
range for each classification.
Storage and Reticulation System
SKN 4223
13
Before gas distributed to the user, it passes
through a series of gas stations in the system.
1. Local Stations
2. Area Station
3. Service Station
Installation of the stations subject to the pressure
required by the user.
Pressure reduced using pressure regulator.
Odorizer included for security purposes.

Storage and Reticulation System
SKN 4223
14
BASIC CONSIDERATION IN SELECTING
THE DISTRIBUTION SYSTEM
Three main factors should be considered:
1. Estimates the gas consumption rate or gas
demand
2. Selection and assumption of distribution
system (Network analysis)
3. Check the pressure required whether it is
maintained at a specific level

Storage and Reticulation System
SKN 4223
15
DESIGN DEMAND ESTIMATION
Determination of the total amount of gas
consumption is among the first requirements for
the determination of the pipe diameter.

What is required for the determination of the
total amount of gas consumption is the amount
of gas consumption of each combustion
appliances and the number of such appliances to
be installed.

It can be determined directly from manufacturer.

Storage and Reticulation System
SKN 4223
16
Appliances Rating (Btu/hr)
Range, Free Standing Domestic
Built-In Oven or Boiler Unit, Domestic
Built-In Top Unit, Domestic
Water Heater, Automatic Storage (30 to 40 gal tank)
Water Heater, Automatic Storage (50 gal tank)
Water Heater, Automatic Instantaneous:
Capacity : 2 gal. per minute
Capacity : 4 gal. per minute
Capacity : 6 gal. per minute
Refrigerator
Gas Light
Incinerator, Domestic
65 000
25 000
40 000
45 000
55 000

142 800
285 000
428 000
3 000
2 500
35 000
Storage and Reticulation System
SKN 4223
17
However, the amount of gas consumption
can be determine based on various factors
Number of customer
Type of residence
Fuel supply and demand situation
Kind of industries
Future prospect of the subject area

Storage and Reticulation System
SKN 4223
18
In general the total amount of all rating of
appliances does not always amount of the gas that
each consumer uses. This is because, it is rarely the
case that consumers use all their appliances
simultaneously and the appliances are not always to
be used with the fully open.
Therefore, the amount of gas to be considered as a
design consumption is a total gas consumption
the area multiply with consumption factor which is
called appliance gas coincident factor.
Storage and Reticulation System
SKN 4223
19
REQUIRED INFORMATION FOR
SERVICE PIPELINE DESIGN
The following information should be obtained:
Plant layout
Overall plant layout
Part of plant layout where firing equipment is located
Location of each burner system
Required pressure of each equipment
Future demand
Location of natural gas service station and for LPG user
Existing LPG piping layout (This drawing must be
checked to confirm its actual installation)
LPG supplied pressure
If possible, former LPG piping contractor name
Storage and Reticulation System
SKN 4223
20
PIPELINE ROUTE SELECTION
Avoid side slopes and cross slopes
Avoid unstable slope
Avoid any crossing, if possible
river, highway, culvert etc
cross at straight section
Avoid cemeteries
Avoid national park or reserve land
Avoid religious places
Avoid community places
Avoid pocket land
Storage and Reticulation System
SKN 4223
21
ROUTE OF SERVICES PIPING
SELECTION & CONSIDERATIONS
Following is the criteria to be considered to select services piping
route.
Exposed piping is much better than underground piping for
easy maintenance and safety
Gas piping shall not be installed in/at/through the following
places or locations:
a lift shaft
exhaust duct, etc.
electrical facility room, etc.
where it will be subjected to extreme temperature, water
or moisture continuously
where it will be subjected to excessive vibration
where it will be subjected to corrosive gas or solution
in concrete slab or cylinder
Storage and Reticulation System
SKN 4223
22
Gas piping shall be securely supported to avoid strain
exerting on the pipe. Therefore good pipe support
must be considered too.
The piping and its support must not obstruct the
operation of any factory's mobile machine i.e. forklift
and crane.
Planning or possible expansion or modification of
factory
where the future demand will be
whether the construction (of the expansion) will
cause unsafe condition or modification required
to the piping system.
Storage and Reticulation System
SKN 4223
23
The construction or installation work of the
piping shall least affect the production or
operation of the factory.
PE pipe shall not be installed as exposed pipe.
The radius of the inner curve of PE pipe
bending (R) shall not less than 25 times of inner
diameter of the pipe.

Storage and Reticulation System
SKN 4223
24
Location of customer's monitoring meter and
line of equipment/regulator shall be located in
ventilated spaces readily accessible for
examination, servicing or replacement.
Piping system shall be as simple as possible to
avoid confusion, especially in case of existing
LPG piping remained.
The loop of piping shall not be use for internal
piping
Storage and Reticulation System
SKN 4223
25
SIZING OF GAS PIPING FOR
SERVICE LINE
Is a line connected from the street main to the
customer's meter.
Gas piping shall be of such size and so installed
as to provide a supply of gas sufficient to meet
demand without undue pressure drop between
service station and gas appliances.

Storage and Reticulation System
SKN 4223
26
Several points need to be considered when sizing the
pipe;
2 and 5 inches pipe shall not be used for new
piping system except for a special case. These two
pipes are not common in the market.
The pipe size of the piping system shall not be
changed except for branches and connection for
meters, regulators, isolation valves or special case
such as tie-in point to existing piping etc.
The pipe size of the downstream pipe shall not be
larger than upstream except the connection for
meters, regulators, isolation valves etc. And the
downstream pipe of meters or regulator must be
adequate size for distributing condition.

Storage and Reticulation System
SKN 4223
27
The minimum pipe size for welding is recommended to be
1 inch.
Factors influence the service line sizing are:
Total connected load
Length of service line
Pressure at the main
There are four methods widely used to solved the above
task as called a quit and simple calculation (not as complex
as general gas flow equation).
NFPA No. 54 (National Fire Protection Association)
Method
Clifford Method
Cox's Formula
Paulss Formula


Storage and Reticulation System
SKN 4223
28
Elevation Effect to Low Pressure
System
Consider gas with specific gravity of S at static
height of 1m:
At datum:
Atmospheric pressure : Pa mbar
Gauge Pressure : Pg mbar
Absolute pressure : Pa + Pg mbar

Storage and Reticulation System
SKN 4223
29
At 1m height, gauge pressure lower by

gas
x g x H.
Storage and Reticulation System
SKN 4223
30
At 1m height, atmospheric pressure is lowered
by p
air
x g x H.




p
air
= 1.2248 kg/m
3

Storage and Reticulation System
SKN 4223
31
Therefore,





It shows that, the pressure drop for low pressure system
is:
0.12 (1 - S) mbar/m

Storage and Reticulation System
SKN 4223
32
COX'S FORMULA
Supply Pressure is/above 29.4 kPa.G (3000
mmH
2
O).
The pipe size of each section or portion shall be pre-
determined by using Table, which shows the
maximum flow capacity at various pressure to ensure
the flow velocity at various pressure to ensure the
flow velocity does not exceed 20 m/s.
Storage and Reticulation System
SKN 4223
33
Storage and Reticulation System
SKN 4223
34
In case that supply pressure is not available in the Table,
the maximum flow capacity of each pipe at 20 m/s can
be calculated as below:



where,
Q
max
: Maximum flowrate (Sm
3
/hr) at 20 m/s flow
velocity
P
s
: Supply pressure (kPa.G)
D : Pipe inner diameter (mm)
101.3 : Atmospheric pressure in kPa
Q
max
=
1. 8
10
2
x t x D
2
x
101. 3 + P
s
101. 3

Storage and Reticulation System
SKN 4223
35
The pressure drop of the size pre-determined above
to each appliance system shall be calculated by Cox's
Formula as shown below: However, maximum
allowable pressure drop is 15% of supply pressure. If
not, shall select bigger pipe size for that sections to
provide the sufficient pressure or pressure drop
within 15% of supply pressure.
In that case, piping cost effect should be also taken
into consideration, so that 2 or more piping sections
or portions might be selected to bigger pipe size.
This mean that, the down stream pipe size must be
bigger size than upstream pipe.
Storage and Reticulation System
SKN 4223
36






Where,
P
1
& P
2
: Absolute pressure (kPa.abs) = Gauge Pressure
(kPa.G) + Atmospheric Pressure (101.325 kPa)
S : Specific Gravity
Q : Flowrate (Sm
3
/hr)
L : Distance (m)
D : Pipe Inner Diameter (mm)
K : Cox's Coefficient = 1.69 x 10
-3

Q = K
(P
2
1
P
2
2
) D
5
S L
P
2
= P
2
1

S Q
2
L
K
2
D
5
Storage and Reticulation System
SKN 4223
37
Example 1
Determine pipeline sizing of a domestic installation
diagram shown below. Assume SG = 0.6
Storage and Reticulation System
SKN 4223
38
Solution
a) Piping Diagram
Storage and Reticulation System
SKN 4223
39
b) Design flowrate and pre-determined

Node No. Flowrate Sm
3
/h Pipe Size (inch)
0-1 395 3 (2 )
1-2 95 1
2-3 35
2-4 60 1
1-5 300 2
Storage and Reticulation System
SKN 4223
40
c) Pressure Drop Calculation
As supply pressure is 138 kPa.G, the minimum
pressure to the equipment is 117.3 kPa.G (218.6
kPa.abs). Therefore, pressure drop of each pipe as
shown in the following table.

Storage and Reticulation System
SKN 4223
41
Node No. Flowrate
(Sm
3
/h)
Length
(m)
Pipe size
(inch)
Pipe size
(mm)
P
1

(kPa.abs)
P
2

(kPa.abs)
Remarks
0-1 395 100 3 77.92 239.3 236.7
1-2 95 70 1 26.64 236.7 222.1
2-3 35 65 20.96 222.1 211.8 <218.6
2-4 60 40 1 26.64 222.1 216.6 <218.6
1-2 95 70 1 35.08 236.7 233.1
2-3 35 65 20.96 233.1 227.8 >218.6
2-4 60 40 1 26.64 233.1 227.8 >218.6
1-5 300 50 2 52.48 236.7 231.2 >218.6
Storage and Reticulation System
SKN 4223
42
d) Result
Storage and Reticulation System
SKN 4223
43
Example 2
A horizontal liquefied petroleum gas pipeline planned to be
installed a the Gas Engineering Laboratory as shown in
figure. Liquefied petroleum gas is supplied through a bulk
tank, which has a wetted area of 90 square feet and a
minimum rate of evaporation of 13.3875 Ib/hr. The Gas
Engineering Department has signed the agreement with a
supplier for the supply of liquefied petroleum gas
composition as shown in table in order to achieve the latent
heat of evaporation and the heat of combustion are 160
Btu/Ib and 21422 Btu/Ib, respectively. If the surrounding
temperature and overall heat transfer coefficient is 80
o
F and
3 Btu/ft
2
.
o
F respectively, calculate the pipe size of each
section involved.
Storage and Reticulation System
SKN 4223
44
Composition Percent Volume
Propane 55
i-butane 30
n-butane 15
Storage and Reticulation System
SKN 4223
45

( )
F T
T
T A Q
h Btu
L Q
h lb Q
o
v
R
06 . 72
80 90 3 2142
'
/ 2142
160 3875 . 13
3875 . 13 '
/ 3875 . 13
2
2
=
=
A =
=
=
=
=
u
vap
A A A A
P x P y P = =
Storage and Reticulation System
SKN 4223
46
Comp %V V (gal)
(Ib/gal)
W MW mol x P
vap
at
72.06
o
F
x. P
vap
y y.MW
C3 55 0.55 4.16 2.288 44 0.052 0.5843 150 87.645 84.33 37.1052
n-C4 30 0.30 4.81 1.443 58 0.025 0.2809 34 9.5506 9.19 5.3302
i-C4 15 0.15 4.64 0.696 58 0.012 0.1348 50 6.740 6.48 3.7584
0.089 103.9356 100 46.1938



60 1
96 28
1938 46
96 28
.
.
.
.
AMW
SG = = =
Storage and Reticulation System
SKN 4223
47

Storage and Reticulation System
SKN 4223
48
Supply Pressure = 100 kPa.gauge
Minimum Pressure = 85 kPa.gauge =186.3 kPa.abs
Pre-determine


Node Q (Sm
3
/h) Pipe size (inch)
0-1 395 2 (3)
1-2 95 1
2-3 35
2-4 60 1
1-5 300 2




( )
5
2
3
2
2
1 2
10 69 . 1 D x
L SQ
P P

=
Storage and Reticulation System
SKN 4223
49
Node No. Flowrate
(Sm
3
/h)
Length
(m)
Pipe size
(inch)
Pipe size
(mm)
P
1

(kPa.abs)
P
2

(kPa.abs)
Remarks
0-1 395 100 3 77.92 201.3 198.2
1-2 95 70 1 35.08 198.2 193.9
2-3 35 65 20.96 193.9 182.0 < 186.3
2-4 60 40 1 26.64 193.9 187.5 > 186.3
2-3 35 65 1 26.64 193.9 190.3 > 186.3
1-5 300 50 2 52.48 198.2 191.6 > 186.3
Storage and Reticulation System
SKN 4223
50
Storage and Reticulation System
SKN 4223
51
PAUL'S FORMULA
Supply Pressure is less than 29.4 kPa.G (3000 mmH
2
O)
Pressure drop of each section can be calculated by Paul's
Formula as shown below:

P : Pressure drop (Pa)
K
2
: Paul's coefficient
= 7.09 x 10
-4
D : Pipe inner diameter (mm)
S : Specific gravity of gas
L : Pipe length (m)
Q : Flowrate (Sm
3
/hr)


Q = K
2

AP D
5
S. L
or
AP =
S
K
2
D
5
x Q
2
L

Storage and Reticulation System
SKN 4223
52
The Paul's Formula can be simplified as the
following formula which is based on Tokyo
Gas experiences.



P : Pressure drop (Pa)
L : Pipe length (m)
Q : Flowrate (Sm
3
/hr)

AP = K
'
2
Q
2
L
Storage and Reticulation System
SKN 4223
53
where, K'
2
as shown in table below. (K'
2
is also taken
into consideration of the pressure drop at fittings).

Nominal Pipe Size
(inch)
K
2
Nominal Pipe Size
(inch)
K
2
5.20 3 6.67 x 10-4
3/4 8.80 x 10-1 4 3.94 x 10-5
1 2.37 x 10-1 6 3.94 x 10-5
1 1/4 5.31 x 10-2 8 3.02 x 10-6
1 1/2 2.29 x 10-2 12 4.14 x 10-7
2 7.85 x 10-3
Storage and Reticulation System
SKN 4223
54
If the supply pressure is very low, the pressure
differences caused by difference of pipe level cannot
be neglected. Therefore, pressure differences shall be
considered and calculated by the formula as shown
below.
AP
H
= p . g. (1 S). AH = 12. 68 x (1 S). AH
AP
H
: Pressure difference (Pa)
p : Density of air (1. 293 kg/Nm
3
)
S : Specific gravity of gas
AH : Difference of pipe level (m)
g : Gravity acceleration (9. 807 kg/s
2
)
Storage and Reticulation System
SKN 4223
55
If level of the node is higher than level of the last
node, the pressure drop is P pressure calculated by
Paul's Formula minus PH.
The pre-determined of pipe size shall be named as
node number normally as node 0 (started - service
station), the next branch is named as node 1 and to
the end by following manner:

1. The longest length of piping from node n to the
end value shall be measured (Ln)
Storage and Reticulation System
SKN 4223
56
2. Calculate the K value with below formula:

K =
AP
n. max
Q
2
n
L
n
AP
n. max
= AP
n 1. max
AP
n1
AP
n. max
: Maximum allowable pressure drop from node n to the end value
AP
n1
: Pressure drop of section n1 calculated by determined pipe size
Q
n
: Design flowrate of section n
Storage and Reticulation System
SKN 4223
57
3. Compare K value to K'2 value shown in the
table. Then find out the appropriate pipe size of
corresponding K'2 (the value selected for K'2
should be less than K value). The selected pipe
size is known as pre-determined pipe size for
section n.
4. APn shall be calculated by Paul's Formula
5. Repeat (1) (4) to determine the pipe size of
section n + 1 until the end section.

Storage and Reticulation System
SKN 4223
58
Example
Determine the pipe size below. The maximum allowable
pressure drop is 3 kPa.
Storage and Reticulation System
SKN 4223
59
Solution
Storage and Reticulation System
SKN 4223
60
Pre-determine pipe size
The most long pipe length from service station to
equipment is 0 - 4. Then,
Node 0 to Node 1
K =
AP
n. max
Q
2
n
. L
n
=
3000
90
2
x 100
= 3. 7 x 10
3
Therefore : Pipe Size = 3"
Pressure drop = K
'
2
Q
2
L
= 6. 67 x 10
4
x 90
2
x 10 = 54. 0 Pa
Storage and Reticulation System
SKN 4223
61
Node 1 - Node 2
K =
AP
n. max
Q
2
n
. L
n
=
3000 54
60
2
x 90
= 9. 1 x 10
3
Therefore : Pipe Size = 2"
Pressure drop = K
'
2
Q
2
L
= 7. 85 x 10
3
x 60
2
x 30 = 847. 8 Pa
Storage and Reticulation System
SKN 4223
62
Node 2 - Node 3
K =
AP
n. max
Q
2
n
. L
n
=
3000 54 847. 8
20
2
x 20
= 2. 6 x 10
1
Therefore : Pipe Size = 1"
Pressure drop = K
'
2
Q
2
L
= 2. 37 x 10
1
x 20
2
x 20 = 1896 Pa
Storage and Reticulation System
SKN 4223
63
Node 2 - Node 4
K =
AP
n. max
Q
2
n
. L
n
=
3000 54 847. 8
40
2
x 60
=2. 19 x 10
2
Therefore : Pipe Size = 2"
Pressure drop = K
'
2
Q
2
L
= 7. 85 x 10
3
x 40
2
x 60 = 753. 6 Pa
Storage and Reticulation System
SKN 4223
64
Node 1 - Node 5
K =
AP
n. max
Q
2
n
. L
n
=
3000 54. 0
30
2
x 5
= 6. 5 x 10
1
Therefore : Pipe Size = 1"
Pressure drop = K
'
2
Q
2
L
= 2. 37 x 10
1
x 30
2
x 5 = 1066. 5 Pa
Storage and Reticulation System
SKN 4223
65
Determination of pipe size

Node Flowrate
(Sm
3
/h)
Length
(m)
Pre-Size
(inch)
P
(Pa)
Pipe Size
(inch)
P
(Pa)
0 1 90 10 3 54.0 2 635.8
1 2 60 30 2 847.8 2 847.8
2 4 40 60 2 753.6 2 753.6
0 4 1655.4 2237.2
2 3 20 70 1 1896.0 1 424.8
0 3 2797.8 1908.4
1 5 30 5 1 1066.5 1 1066.5
0 5 1120.5 1702.3
Storage and Reticulation System
SKN 4223
66
NFPA 54
Noted for simplicity
Given a length and the maximum load, the required
pipe size is read directly from the table
Following factors are required.
1) Allowable loss in pressure from point of delivery to
equipment
2) Maximum gas demand
3) Length of pipe from the point of delivery to the
most remote
4) Specific gravity of gas
5) Diversity factor
Storage and Reticulation System
SKN 4223
67
Capacities for low pressure (0.5 psig or less) in cubic
feet per hour of 0.60 specific gravity for different length
are shown in Table 13 to Table 16 ( MS 930) for iron
pipe or equivalent rigid pipe.
- Table 13 and 15 are based upon a pressure drop
0.3 inches water column
- Table 14 and 16 are based upon a pressure drop
0.5 inches water column
- Table 26 is used when capacities in thousands of
BTU per hour of undiluted liquefied petroleum
gases based on pressure drop 0.5 inches water
column.
Storage and Reticulation System
SKN 4223
68
Storage and Reticulation System
SKN 4223
69
Storage and Reticulation System
SKN 4223
70
Storage and Reticulation System
SKN 4223
71
Storage and Reticulation System
SKN 4223
72
Storage and Reticulation System
SKN 4223
73
If the data does not give the exact value, select the
column showing the next larger
If the gravity of gas is different with table 13 to 16,
use the gravity factor in Table 25
In using these tables no additional allowance is
necessary for an ordinary number of fittings.
Storage and Reticulation System
SKN 4223
74
Storage and Reticulation System
SKN 4223
75
Example
Determine the required pipe size of each section and
outlet of the piping system shown below. Given gas
gravity 0.65, designed pressure drop is 0.5 inches water
column and gas heating value is 1000 BTU/CF.
Point of delivery
Outlet C
Range:
75,000 Btu/hr
Outlet B
Gas refrigerator:
3,000 Btu/hr
Outlet A
Water heater:
30,000 Btu/hr
Outlet D
Furnace:
136,000 Btu/hr
10 '
20 ' 10 '
15 '
20 '
10 '
10 '
5'
Section 3 Section 2 Section 1
Storage and Reticulation System
SKN 4223
76
Solution
Step 1
Maximum gas demand at each outlet
= Consumption Rating (Btu/hr)
Heating Value of Gas (Btu/cf)

Outlet A = 30,000/1000 = 30 cfh
Outlet B = 3,000/1000 = 3 cfh
Outlet C = 75,000/1000 = 75 cfh
Outlet D = 136,000/1000 = 136 cfh
Storage and Reticulation System
SKN 4223
77
Step 2

Length of pipe from the point of delivery to the
most remote outlet (A) = 60 ft

Step 3

Refer to table which follow the above
specification. Read under column length of 60 ft.
Storage and Reticulation System
SKN 4223
78
Section Outlet Demand
(cfh)
Pipe Required
(inches)
1 A
B
30
3
3/8
1/4
A + B 33 3/8
2 C 75 3/4
A+B+C 108 3/4
3 D 136 3/4
A+B+C+D 244 1
If the gravity factor is applied to this example, the value in the
column marked 60 feet of Table 14 would be multiplied by the
multiplier 0.96 from Table 25 and resulting cubic feet per hour
values would be used to size the piping.
Storage and Reticulation System
SKN 4223
79
Based on SG 0.6
at 60 feet (cfh)
Multiplier 0.96
(cfh)
Nominal Iron Pipe Size
(inches)
16 15.36 1/4
36 34.56 3/8
68 65.28 1/2
178 170.88 3/4
260 249.60 1
520 499.20 1 1/4
810 777.60 1 1/2
1520 1459.20 2
2400 2304.00 2 1/2
4300 4128.00 3
8800 8448.00 4
Storage and Reticulation System
SKN 4223
80
Clifford Method
May not be simple but offers the advantage of
flexibility
Can be noted with actual pressure drop and pipe
size
Which ultimately may prove useful when making
adjustments for possible future loads.
Classified by two categories
1) Low pressure line
2) High pressure line
Storage and Reticulation System
SKN 4223
81
Low Pressure Line
Five factors should be considered
i) Pipe length together with additional length of
fitting
ii) Allowable pressure drop
iii) Load or demand
iv) Pipe material
v) Actual pressure drop

Refer to Table 28 and Table 29
Storage and Reticulation System
SKN 4223
82
Storage and Reticulation System
SKN 4223
83
Storage and Reticulation System
SKN 4223
84
Pipe Length
Length 10 - 100 feet
Listed in left hand side of the table
Length > 100 feet
The actual length (plus the allowable for fitting) and
allowable pressure drop are both divided by a
convenient number that will bring the pipe length
within the range of the table
Storage and Reticulation System
SKN 4223
85
Example
280 ft line with allowable pressure drop 0.6 inches
water column.

The pipeline would be properly sized if the length is
considered to be 70 (divided by 4) and the allowable
pressure drop is 0.15 inches water column.

Equivalent length for fitting refer to Table 29.
Commonly, 2 inches pipe size used as a reference. If
the final result (pressure drop) more than allowable
value select the next larger size.
Storage and Reticulation System
SKN 4223
86
Allowable Pressure Drop
Is given over to pressure drop ranging from 0.1 to
1.0 inches water column.
This pressure drops makes the table quit flexible
and allow for appropriate selection.
Allowable pressure drop used is 0.6 inches water
column.
Single line pipeline is direct solving but branch
lines must be sized separately.

Storage and Reticulation System
SKN 4223
87
Load or Demand
Calculate the load it must handle.
A branch line is sized on the basis of the BTU
rating of the appliance it services.
The main line must handle the total load.
An intermediate line will be sized for the
appliances it services.

Storage and Reticulation System
SKN 4223
88
Pipe Material
Four type of piping material system and practitioner
will make his selection on the basis of company
practice.
Actual Pressure Drop
For the more complicated piping system it is helpful to
determine the actual pressure drop for the pipe sized
selected.
Storage and Reticulation System
SKN 4223
89
Example
Determine pipeline sizing of a domestic installation
shown below. Used allowable pressure drop is 0.6 inches
water column.
R
A
B
C
D
15 feet, 0. 34 " WC
5 feet,
0. 26 " WC
10 feet, 0. 26 " WC
10 feet,
0. 26 " WC
Water h eater
30 ,0 00 Btu
Gas Rang e
63 ,0 00 Btu
Floo r furnace
80 ,0 00 Btu
Storage and Reticulation System
SKN 4223
90
Solution
Step 1
Leading to the appliance with the greatest load or input.
Equivalent length:
Main line
Measured length = 15 feet
One 90 degree elbow = 5 feet
Sub-Total = 20 feet
Branch line to floor furnace (The Greatest Load)
Measured length = 5 feet
Tee-Side Outlet = 10.4 feet
Sub-Total = 15.4 feet

Storage and Reticulation System
SKN 4223
91
Total pipe length from furnace to the pressure
regulator is 35.4 feet
Since the main line is 0.57 of total length involved and
0.57 pressure drop of 0.6 inches water column is 0.34
inches water column. So allowable pressure drop on
each branch line is 0.26 inches water column
Storage and Reticulation System
SKN 4223
92
Step 2

Load demand based on figure:
Gas range = 63,000
Water heater = 30,000
Floor furnace = 80,000
Total Load = 173,000 Btu

Storage and Reticulation System
SKN 4223
93
Step 3

Can select out of 4 type of piping material (use Table 28)

Main line
Pipe Sizing
Pipe length 20 ft and 0.34 " W.C. (allowable pressure drop)
(Select the suitable piping material) to the total load 173,000
Btu (if not available, look the next larger i.e. 321,000 Btu -
interpolation).
Answer = " IPS
Storage and Reticulation System
SKN 4223
94
Storage and Reticulation System
SKN 4223
95
Actual Pressure Drop

From 3/4 inch IPS, proceed to RHS to 175,000 BTU
(nearest to 173,000 Btu).

Then proceed upward until in line with the pipe
distance 20 ft.
Answer = 0.1 inches water column

Storage and Reticulation System
SKN 4223
96
Storage and Reticulation System
SKN 4223
97
Branch Line B

Pipe sizing and actual pressure drop

Use the similar way as above (main line)
Pipe length
= 20 ft (10 ft. measured length + 10 ft. Tee-Side)

Allowable pressure drop = 0.26 " W.C.
Load (63,000 Btu) = 109,000 Btu (interpolation)
Pipe size = 1/2 " K Tubing
Actual pressure drop = 0.1" W.C.
(Nearest load = 68,000 Btu)

Storage and Reticulation System
SKN 4223
98
Branch Line C

Pipe sizing and actual pressure drop. Use the similar way as
above (main line).

Pipe length
= 20 ft (10 ft. measured length + 10 ft. Tee-Side)

Allowable pressure drop = 0.26 " W.C.
Load (30,000 Btu) = 54,000 Btu (interpolation)
Pipe size = 3/8 " K Tubing
Actual pressure drop = 0.08" W.C.
(Nearest load = 31,000 Btu)

Storage and Reticulation System
SKN 4223
99
Branch Line D

Pipe sizing and actual pressure drop. Use the similar way as
above (main line).

Pipe length
= 15 ft (5 ft. measured length + 10 ft. Tee-Side)

Allowable pressure drop = 0.26 " W.C.
Load (80,000 Btu) = 126,000 Btu (interpolation)
Pipe size = 1/2 " K Tubing
Actual pressure drop = 0.11" W.C.
(Nearest load = 84,000 Btu)

Storage and Reticulation System
SKN 4223
100
High Pressure Line
If an appliance requires gas at a pressure of 10 psig or
15 psig for proper operation, it will have to supplied by
a high pressure gas line.

The carrying capacity of a pipeline is 10 times or 15
times greater with high pressure gas than with low
pressure.
- Table 31 to Table 34 (MS 930) have to be used
for Option 1
- Chart in Figure 19 (MS 930) has to be used for
Option 2.
Storage and Reticulation System
SKN 4223
101
The increased capacity depends, of course on the
pressure at which the gas is piped and allowed pressure
drop.
If an existing low pressure line has become overload, its
capacity may be increased considerably by increasing the
pressure by only a few pounds.
In many such cases it would be less expensive and
provide better performance to change to two-stage
regulator rather than replace the existing low pressure
line.
Storage and Reticulation System
SKN 4223
102
Table 31 (MS930)
Storage and Reticulation System
SKN 4223
103
Storage and Reticulation System
SKN 4223
104
Storage and Reticulation System
SKN 4223
105
Storage and Reticulation System
SKN 4223
106
Example (Table 31)
A commercial installation is to be made in a northern
area where the lowest temperature to be accounted is -
15
o
F. The pipe length is 40 ft and the maximum load is
650,000 Btu. Determine the required pipe size for
intermediate pressure line when two-stages regulator
will used.
Storage and Reticulation System
SKN 4223
107
Solution
Step 1
Referring to the key at the bottom of Table 31, it will be noted that for
a minimum temperature -15
o
F, the B capacities should be used.

Step 2
Select 40 ft in the left hand column of the table and use the pipe
capacities shown opposite the letter B.

Step 3
Since the Figure 650, representing the load in thousands of Btu does
not appear in the horizontal line opposite 40 ft B the next higher figure
870 is selected.
Storage and Reticulation System
SKN 4223
108
Step 4
Moving upward from the 870 just selected the
required pipe size is found to be inch type K
tubing. By following the same procedure in the
right of the table, inch pipe will be indicated
for this installation.

Note: For sizing high pressure lines involving
factors beyond the scope of the simplified in
Table 31, Table 32 to Table 35 are
recommended.

Storage and Reticulation System
SKN 4223
109
Example (Option 1)
Determine the proper pipe sizes for the high piping
system shown below. The maximum allowable
pressure drop between the high pressure regulator
outlet and several appliances is 5 psig
R
L1 20 0 feet
L4
20 feet
L2 2 5 feet
L3
20 feet
2, 00 0, 000 Btu
1, 50 0, 000 Btu
3, 00 0, 000 Btu
Delivered
pressure
10 p sig
Initial
pressure 15 psig
Storage and Reticulation System
SKN 4223
110
Step 1

An arbitrary decision must be made as to how this will
be apportioned.
Suggested:
Main line = 3 psi
Each branch = 2 psi

Therefore, delivered pressure for the main line will be
12 psi and this will then be the initial pressure for the
branch lines.

Storage and Reticulation System
SKN 4223
111
Step 2

Referring to Table 33.

15 psi initial pressure it will be seen that the value
of 'h' for 3 psi pressure drop is 169.

For each branch lines the initial is 12 psi and the
pressure drop is 2 psi. For this pressure drop and
initial pressure the value of 'h' is 103

Storage and Reticulation System
SKN 4223
112
Step 3
Size the main line

Pipe length = 200 ft
Value of 'h' = 169
Load = 6500 thousand Btu (total load)

Since 200 ft is not shown in the pipe sizing table. It is necessary to make
adjustment such as the following:

200 ft value of 'h' 169
100 ft value of 'h' 85

In table 32, the values 80 and 90 are found for 'h'. Since 85 is haft way
between, one can follow down between the two line to the standard pipe
section.

The indicated pipe sized = 1 1/4 IPS

Storage and Reticulation System
SKN 4223
113
However, the actual value of 'h' can be estimated.
Find 6500 in the horizontal line opposite to 1
IPS: 6684 is selected

Proceed upward to the 100 ft line it is seen that the
actual value of 'h' appears to be 40. Since pipe
length and 'h' were divided by 2, it is necessary now
multiply by 2 to get the true value of 'h' for the size
selected.

Storage and Reticulation System
SKN 4223
114
Size the line 2

Pipe length = 25 ft
Value of 'h' = 103
Load = 3000 thousand Btu

Since 'h' with 103 is not shown in the pipe sizing table. It is
necessary to make adjustment such as the following:

The value of 'h' and the load by 4, as follow;
Value of 'h' 103
Value of 'h' 26

Load 3000 thousand Btu
Load 750 thousand Btu
Storage and Reticulation System
SKN 4223
115
The problem can now be solved on the basis of the
following factors:
Pipe length = 25 ft
Value of 'h' = 26
Load = 750 thousand Btu

Using table as already explained;

Pipe size = IPS
Value of 'h' = 10 x 4 > (chart shown factor)
= 40

Storage and Reticulation System
SKN 4223
116
Size the line 3

Solved in the same manner and the following factors being used with
the pipe sizing table.
Pipe length (2 ells) = 30 ft
Value of 'h' = 26
Load = 500 thousand Btu

Value of 'h' 103
Value of 'h' 26
Load 2000 thousand Btu
Load 500 thousand Btu

Pipe sized = IPS
Actual value of 'h' = 6 x 4
= 24

Storage and Reticulation System
SKN 4223
117
Size the line 4

Sizing line 4 follow the same procedure:

Pipe length (2 ells) = 30 ft
Value of 'h' = 26
Load = 375 thousand Btu
Value of 'h' 103
Value of 'h' 26
Load 1500 thousand Btu
Load 375 thousand Btu

Pipe sized = IPS
Actual value of 'h' = 3 x 4 = 12

Storage and Reticulation System
SKN 4223
118
Example (Option 2)
Find the proper size of standard weight pipe for a
1000 ft line which is to carry a load of 10,000,000
Btu/h. The initial pressure is 20 psi and the pressure
drop is limited to 3 psi.
Storage and Reticulation System
SKN 4223
119
Storage and Reticulation System
SKN 4223
120
Solution
Step 1

Refer to table 33 : h = 199
Use Figure 19.
Align this point on Figure 19 with 1000 ft and
extending to Line 3.

Step 2

Align point on Line 3 with 10,000 of Scale 4 and
extend to Scale 5. However, no pipe size can be read
because out of range (no intersection).

Storage and Reticulation System
SKN 4223
121
Storage and Reticulation System
SKN 4223
122
Step 3

Divide the 10,000 thousand Btu by 10 and repeat
Step 2.
Pipe size in between 1 " and 2 "
Answer: Select pipe size with 2 "


Storage and Reticulation System
SKN 4223
123
Storage and Reticulation System
SKN 4223
124
Step 4

To find actual pressure drop with pipe size selected,
reversed the above procedure.

Start with 2" pipe size.
Answer :
h value = 110
pressure drop in between 1 psi and 2 psi.

Storage and Reticulation System
SKN 4223
125
Storage and Reticulation System
SKN 4223
126
BUOYANCY CONTROL
Pipeline are subject to buoyant forces when they
encounter free-standing or flowing water at river
crossing, streams and lakes and when buried in the
saturated soils generally present in flood plains,
marshes, swamps, muskeg (bogs) and local depressions.
Storage and Reticulation System
SKN 4223
127
There are two principles reasons for counteracting the
buoyant force exerted on a pipeline system:

i) to submerge the pipe in a water-filled ditch
during construction prior to backfilling

ii) to prevent the pipe from floating or rising off at
the ditch bottom during the post installation
period and during operation of the pipeline.

Storage and Reticulation System
SKN 4223
128
Potential areas requiring buoyancy control can be
classified into four brad categories:

i) river crossings
ii) stream or creek crossings
iii) muskeg or bogs crossing
iv) soil which have the potential to act as a fluid

Storage and Reticulation System
SKN 4223
129

Buoyancy control may be achieved in three ways:

i) mechanical anchoring system








They are not commonly used for large diameter
pipelines
Storage and Reticulation System
SKN 4223
130

ii) Backfill

Using either native or borrowed material for buoyancy control,
relies on the mass of the backfill over the pipe to counteract the
buoyancy forces.
Native backfill may be considered if it consists of stable, ice-free
soil which is capable of achieving a reasonable level of strength.
If the native backfill is not adequate, select backfill can be used.
Select backfill should be coarse-grained, free draining material
exhibiting sufficient shear strength when thawed or mixed with
water.
Although gravel is undoubtedly the best material, other materials
such as a mixture of gravel, sand, clay and silt can be used
Storage and Reticulation System
SKN 4223
131

iii) density anchoring system

Density anchors are a system of weight added to
the pipeline.

The types of anchors usually in the form of
concrete are
1. swamp weights (saddle or set-on weights)
2. river weights (bolt-on)
3. continues concrete coating.

Storage and Reticulation System
SKN 4223
132

Hook
Reinforced Bar
Wire
Mesh
Rockshield
Storage and Reticulation System
SKN 4223
133

Hook
Rockshield
Wire Mesh
Bolt
Steel
Tubing
Storage and Reticulation System
SKN 4223
134

Concrete Minimum
Thickness, T
FBE Coating or
equivalent
Compressible
Material of Coating
Protection
Wire
Mesh
Compressible
Material
Storage and Reticulation System
SKN 4223
135
ANCHOR SELECTION
Final selection of the type and extent of buoyancy control
measures should be made on a site-specific basis, taking the
following into consideration:
i) type of terrain
ii) type of soil
iii) ditch conditions (dry or wet)
iv) construction season
v) cost (economics)
vi) availability of materials
vii) access to site
viii) ease of handling during transport and construction
ix) limitations of equipment
Storage and Reticulation System
SKN 4223
136
ANCHOR DESIGN
CONSIDERATION
In general, design of buoyancy control system are based
on location conditions. For example, the following
values or factors are incorporated into design
calculation in Canada:

i) For river flood plains, small streams, drainage course,
swamp, muskeg, small lakes and local depression where
water will be encountered in the ditch during
construction:
Negative Buoyancy : 5%
Fluid Density : 1040 kg/m
3
Storage and Reticulation System
SKN 4223
137
For main river channels and areas where flowing or
moving water will be encountered during
construction:

Negative Buoyancy : 10 %
Fluid Density : 1000 kg/m
3


Storage and Reticulation System
SKN 4223
138
However, in Malaysia design of buoyancy
control system is constant which is based on
negative buoyancy as 20 percent in all conditions
and density of fluid is 1000 kg/m
3
.
Storage and Reticulation System
SKN 4223
139
PIPELINE TESTING
Pipeline testing required if the pipeline operates at
Hoop Stress of more than 30% of SMYS.
Required to ensure that all connections are sealed and
without expansion
performed after completion of installation activities
except tie-in part or the location of the testing is not
appropriate.
Required by all code-gas code of practice
It should be witnessed by the local gas inspector to
make verification

Storage and Reticulation System
SKN 4223
140
There are two types of pipeline tests carried out
1. Hydrostatic test - test medium: water or methanol
2. Pneumatic test - test medium: compressed air or
inert gas
Test pressure must be higher than the maximum
operating pressure and is usually 1.5 times the
design pressure.
Storage and Reticulation System
SKN 4223
141
An important aspect of any operational testing is complete
and accurate documentation - records remain as long as the
equipment or piping is used.
According to the Federal Pipeline Safety Regulations, USA,
records must have the following information:
1. Pressure record chart
2. Equipment calibration test data
3. Name of the responsible operator
4. Date and time of test
5. Testing pressure
6. Testing medium
7. Description of testing equipment
8. Comments
Storage and Reticulation System
SKN 4223
142
HYDROSTATIC TEST
General Guideline- Testing Part
1. Pipe Length < 16 km
2. For testing medium other than water, testing
capacity lower than 500 m
3
.
3. Determination of low and high pints, and testing
pressure.
4. Pipe ends nearby water resources are preferred.
5. All parts tested with equal diameter and pressure.
Storage and Reticulation System
SKN 4223
143
Hydrostatic Test Calculation
Using standard forms and determination of the
required pressure test involving:

1. Location of the test
2. Pipe dimension
3. Low and high pints, and testing pressure.
4. Grade or pipe SMYS
5. Maximum operating pressure
Storage and Reticulation System
SKN 4223
144
Preparation before the
Performing Test
Step 1: Approval to pump the water, if necessary
Step 2: Testing Equipments:
a) Pressure and temperature recorder
b) Test head
c) Dead Weight Tester
d) Pressure and temperature gauge, if necessary
e) Flowmeter
f) Fittings - used to connect all equipment
Storage and Reticulation System
SKN 4223
145
Storage and Reticulation System
SKN 4223
146
Step 3: Water filling
a) Water must not containing mud, floating
materials or corrosive components unless it can
be removed or treated.
b) The filling made with poly pig (front) or coated
form pig.
c) Avoid air trapped in the pipeline
- Will affect the testing process
- Hazardous conditions
d) Check the head to prevent leakage test after
completing the filling of water
Storage and Reticulation System
SKN 4223
147
Total volume of water is determined by the
following methods:
a) The volume of water to be filled for the test:


Where
V = volume of water at 0 psig, gallon
L = length of test pipe, feet
D = internal diameter, inches

L x D x V
2
0408 . 0 =
Storage and Reticulation System
SKN 4223
148
b) The volume required at testing pressure

V
tp
= content of water (gal) at pressure P and
temperature T, gal
F
wp
= compressibility correction factor due to
water pressure changes from 0 psig to the
pressure P test

pwt pp wp tp
F x F x F x V V =
( )

|
|
.
|

\
|

atm
test
wp
P
P
x x
F
5
10 5 . 4 1
1
Storage and Reticulation System
SKN 4223
149
F
PP
= correction factor of the internal volume of the
pipe as a result of pressure changes from 0
psig to the pressure P test



Where
D = external diameter of the pipe, inches
t = pipe wall thickness, inches
T = temperature of pipe,
o
F
( ) | | 60 10 6 . 3 10
30
9 . 0
1
6 6
+

|
.
|

\
|
|
.
|

\
|
+ =

T x x x
P
x
t
D
F
test
pp
Storage and Reticulation System
SKN 4223
150
F
pwt
= volume of water and volume of pipe correction
factor due to temperature changes from base
temperature (60
o
F) to the pipe temperature (
o
F)



F
pt
= pipe volume correction factor due thermal
expansion


F
WT
= specific volume of water correction factor due to
thermal changes.
wt
pt
pwt
F
F
F =
( ) | |
6
10 2 . 18 60 1

+ = x x T F
pt
Storage and Reticulation System
SKN 4223
151
Storage and Reticulation System
SKN 4223
152
Example 1
Calculate the volume of water required
during the filling and pressure testing

Pipe Size: 10.75 inch OD x 0.279 w.t. X52
Length: 5 miles (5280 feet = 1 mile)
Test Pressure: 2430 psig
Temperature: 50
o
F
Storage and Reticulation System
SKN 4223
153
Solution




gallon L x D x V 888 , 111 0408 . 0
2
= =
( )
007479 . 1
73 . 14
10 5 . 4 1
1
5
=

|
.
|

\
|

test
wp
P
x x
F
( ) | | 002804 . 1 60 10 6 . 3 10
30
9 . 0
1
6 6
= +

|
.
|

\
|
|
.
|

\
|
+ =

T x x x
P
x
t
D
F
test
pp
( ) | | 999818 . 0 10 2 . 18 60 1
6
= + =

x x T F
pt
) ( 9993061 . 0 table from F
wt
=
gallon
x x x
F x F x F x V V
pwt pp wp tp
099 , 113
000512 . 1 002804 . 1 007479 . 1 111888
=
=
=
Storage and Reticulation System
SKN 4223
154
Example 2
After some time, testing pressure P was reduced to
2422 psig and temperature of the water and pipe
has been reduced to 48
o
F. Determine the volume
of testing at the time.

Storage and Reticulation System
SKN 4223
155
Solution





000565 . 1
999217 . 0
999781 . 0
002796 . 1
007454 . 1
48
2422
888 , 111
1
1
1
1
1
1
1
=
=
=
=
=
=
=
=
pwt
wt
pt
pp
wp
o
F
F
F
F
F
F T
psig P
gallon V
gallon
x x x
F x F x F x V V
pwt pp wp tp
101 , 113
000565 . 1 002796 . 1 007454 . 1 111888
1
=
=
=
Storage and Reticulation System
SKN 4223
156
Initial volume = 113.099 gallons
Volume of water required fro the second condition=
113.101 gallons

Therefore, 2 gallons of water needed to be added to the
system.
If, more water filled to achieve 2430 psig, the system is
leaking.
Storage and Reticulation System
SKN 4223
157
The Relationship Between
Pressure And Temperature

Estimation of pressure changes due to changes in
water temperature can be determined by the chart.

Performed with the use of charts based on the ratio
between the diameter and thickness of pipe involved.
Storage and Reticulation System
SKN 4223
158
Storage and Reticulation System
SKN 4223
159
Storage and Reticulation System
SKN 4223
160
Storage and Reticulation System
SKN 4223
161
Storage and Reticulation System
SKN 4223
162
Example

Size of pipe = 18 inches OD x 0375 inches w.t.

Initial temperature = 70
o
F

The previous temperature T = 66
o
F

Pressure = 1800 psig test

Storage and Reticulation System
SKN 4223
163
solution




According to the chart available pressure
drop is
F e Temperatur Average
t
D
o
68
2
66 70
48
375 . 0
18
=
|
.
|

\
|
+
=
= =
F per psig P
o
23 = A
Storage and Reticulation System
SKN 4223
164
Step 4: Pressuring
Pressuring - typically use reciprocating pumps up
the pressure leak test
The calculation of pressure tests should consider
the actual height in the area
Pump stopped when the pressure reaches the leak
test pressure for a minimum of 30 minutes (time
stability of the pressure wave)
Visually - check all the connectors
Storage and Reticulation System
SKN 4223
165
Step 5: Test 24 hours (unless specified by the authorities
involved)
Pump to started to increase pressure to test pressure
If the pressure falls more than 70 kPa within two hours, it must
be re-pressurised
Pressure is released through the test head when the pressure
exceeds the test pressure.
24 hours started after the pump is removed from the pipe system
Pressure and temperature recorded for 36 hours
1. Pressure increment
2. Leak testing
3. Period of stability
4. Test within 24 hours (methanol only six hours required)
5. Pressure reduction
Storage and Reticulation System
SKN 4223
166
Step 6: Pressure reduction
Performed after the completion of the test.
Pressure reduced to a maximum of 2000 kPa for
pipes with a diameter of 60.3 mm or more in
order to avoid the effects of vibration - broken
pipe
Water drained away from the pipeline trench.
Storage and Reticulation System
SKN 4223
167
Step 7: Water Draining
Water can be transferred to next part for testing
(if necessary) or be drained to suitable location.
Compressor and poly pig usually used
simultaneously for draining.
Step 8: Drying operation
Pig launched (to remove water from the system)
Pig moved at optimum velocity to remove
maximum volume of contaminants.
This step repeated until satisfied.
Storage and Reticulation System
SKN 4223
168
Step 9: Methanol Cleaning
Methanol used to improve water draining from pipe.
This step performed after water draining and drying
operation step.
Below dew point (methanol help combating hydrate
formation).
Methanol filled between two pigs.
Volume of methanol needed is about 15% of water volume.
Maximum pipe length is 30 km depending on methanol
availability.
Methanol must be ensure do not contacted with soil and not
be drained to ground (it must be stored in suitable container
to be reused)
Storage and Reticulation System
SKN 4223
169
Step 19: Air drying
An alternative to methanol cleaning process
Can be considered if one of the following
conditions happens:
Existence of wet gas
Reasonable cost to replace methanol drying
Moisture content determined periodically at output
using dew point test (Mirror Hydrometer).
Satisfied when dew point reach -45
o
C or lower.
Storage and Reticulation System
SKN 4223
170
Storage and Reticulation System
SKN 4223
171
Storage and Reticulation System
SKN 4223
172
PNEUMATIC TEST
Usually performed by using compressed air
which relatively low cost.

In certain condition, for safety reasons, inert
gas (in cylinder) should be considered.
Storage and Reticulation System
SKN 4223
173
Equipments and Preparation for
the Test
1: Pump and compressor
Small pipe using hand pump (however, it takes longer
time)
For bigger pipe, compressor will be used
Small unit electric powered (several ft
3
/min)
Large unit diesel engine (150 500 ft
3
/min)
2: Compressed air cylinder
Using nitrogen gas or compressed air cylinder
Stored at 2200 psig (15000 kPa)
Available in several size:
70 ft
3
(2 m
3
) to 300 ft
3
(8.5 m
3
)
The capacity shows the volume at atmospheric pressure.

Storage and Reticulation System
SKN 4223
174
3: Liquefied Gas Cylinder
Insulated liquefied nitrogen tank size 100 m3
connected to tanker together with vaporiser.
4: Cylinder System
Gas or compressed air cylinder easier to be used at
site.
Cylinder connected to pipeline system.
The number of cylinder should be determined to
ensure sufficient supply.
Storage and Reticulation System
SKN 4223
175
5: Number of Cylinder
Determined using following steps:
a) Calculate volume of pipeline to be tested:


Where;
V : Pipe Volume (ft
3
or m
3
)
d : Pipe Diameter (ft or m)
L : Pipe Length (ft or m)
L x 7854 . 0 x d V
2
=
Storage and Reticulation System
SKN 4223
176
b) Determine compressed gas size:
Determined either by physical size or volume
at atmospheric pressure.


Example:
Cylinder : nitrogen gas
Physical size : 1.5 ft
3
at 2200 psig
|
|
.
|

\
|
=
2
1
1 2
P
P
V V
pressure c atmospheri at ft
ft V
3
3
2
5 . 225
73 . 14
73 . 14 2200
5 . 1
=
|
.
|

\
|
+
=
Storage and Reticulation System
SKN 4223
177
c) Identify pressure required
Minimum test pressure can be identified by
referring to code of practice
d) Calculate the number of cylinder required
Following data required:
- Volume of pipeline
- Test pressure
- Cylinder capacity
Storage and Reticulation System
SKN 4223
178
example
Calculate the number of gas cylinder required to
perform pneumatic test for the following system:
Pipeline volume : 175 ft
3
Test pressure : 50 psig
Cylinder capacity : 1.5 ft
3
at 2200 psig


Storage and Reticulation System
SKN 4223
179
First nitrogen cylinder connected to the pipeline





|
|
.
|

\
|
=
2
1
1 2
V
V
P P
psia
pipe ft cylinder ft
pipe ft N ft
P
42 . 33
175 5 . 1
175 5 . 225
73 . 14
3 3
3
2
3
2
=
|
|
.
|

\
|
+
+
=
|
|
.
|

\
|
=
2
1
1 2
P
P
V V
3
3
2
4 . 99
42 . 33
73 . 14 2200
5 . 1
ft
psia
psia psig
ft V
=
|
|
.
|

\
| +
=
Storage and Reticulation System
SKN 4223
180
Second nitrogen cylinder connected to the pipeline





|
|
.
|

\
|
=
2
1
1 2
V
V
P P
|
|
.
|

\
|
=
2
1
1 2
P
P
V V
psia P 95 . 51
175 5 . 1
175 4 . 99
42 . 33
2
=
|
|
.
|

\
|
+
+
=
3
2
94 . 63
95 . 51
175 2200
5 . 1
ft
V
=
|
.
|

\
|
+
=
Storage and Reticulation System
SKN 4223
181
Third nitrogen cylinder connected to the pipeline





Therefore, three nitrogen cylinder required.





|
|
.
|

\
|
=
2
1
1 2
V
V
P P
psig or psia
P
6 . 59 32 . 70
175 5 . 1
175 94 . 63
95 . 51
2
=
|
|
.
|

\
|
+
+
=
Storage and Reticulation System
SKN 4223
182
PURGING
Purging operation should be performed to ensure the
pipeline is free from air before commissioning.
Any failure to do the operation may lead to incident
such as fire and explosion that will cause loss in
properties and life.
Purging can be performed through following medium:
Inert gas (nitrogen or carbon dioxide) for pipe with
diameter of 4 inch or more
Natural gas can be used for pipe with diameter less
than 4 inch
Storage and Reticulation System
SKN 4223
183
Velocity of mixture should be more than methane
flame speed which is 120 ft/min (2 ft/s).
Usually the operation performed at 200 ft/min at 8
psig at the outlet point.
This to ensure that, if any spark happens at the
outlet, the flame will not travel inwards the
pipeline.
Storage and Reticulation System
SKN 4223
184
a) Pipe with diameter less than 4 inch
Natural gas or nitrogen can used as the medium to
perform the purging operation.
The procedure are as follows:
Medium: Natural Gas
Check the system layout and note the lower
point, uncontrollable opening and purge point.
Ensure the approval to performed the
operation have been obtained.
Purge point must be more than 0.5 inch


Storage and Reticulation System
SKN 4223
185
The nearest building located more than 10 feet
and the pipeline safe from any spark supply
Purging velocity at purge pint more than 200
ft/min and 8 psig
Purge point must be monitored
The operation stopped when 100% methane gas
observed at the purge point
For a low pressure system, gas can only be burned
only when purging burner is available.
Storage and Reticulation System
SKN 4223
186
Medium: Nitrogen Gas
Calculate number of nitrogen gas cylinder
required
If manifold system used, gas must be flowed
until all gas are used
Pressure at purge point should be maintained at
8 psig and velocity of 200 ft/min
Manifold system and purge point should be
monitored throughout the operation
The operation stopped when 100% nitrogen
Storage and Reticulation System
SKN 4223
187
b) Pipe with diameter of 4 inch or more
Inert gas (nitrogen or carbon dioxide) must be used
The procedure are as follows:
Calculate number of nitrogen gas cylinder required
Manifold system must be used
Manifold system and purge point should be
monitored throughout the operation
Pressure at purge point should be maintained at 8
psig and velocity of 200 ft/min
The system must be gasified after the operation
complete
Storage and Reticulation System
SKN 4223
188
Number of nitrogen gas cylinder required
length pipe x R
length pipe x D x volume pipe
2
2
14 . 3
785 . 0
=
=
013 . 0 x volume pipe required gas nitrogen of number =

Vous aimerez peut-être aussi