DESIGN OF 36” ONSHORE

CRUDE OIL PIPELINE

UNDER GUIDANCE OF: BY
SACHIN SURESH PILLAI
M R . S . P. S A X S E N A ( I N T E R N A L )
R150216014
M R . J O G I N D E R S I N G H I S H A RWA L ( E X T E R N A L )
M.TECH PLE IV
E S S A R E N G I N E E R I N G S E RV I C E S LT D .
 CONTENT
 INTRODUCTION
 BACKGROUND
 OBJECTIVES
 METHODOLOGY
 WALL THICKNESS CALCULATION
 PIPE FLOATATION CALCULATION
 RESULTS
 MS EXCEL WORKSHEET FOR WALL THICKNESS
CALCULATION
 MS EXCEL WORKSHEET FOR PIPE FLOATATION
CALCULATION
 CONCLUSION
 WORKS TO BE DONE
 INTRODUCTION
Pipelines are considered to be one of the most economical way of
transportation of liquid and gaseous products.
There are mainly three phases in the design of a pipeline project:
 Conceptual Design Phase
 Basic Engineering Phase
 Detailed engineering Phase
In this project I will be focusing more on the detailed engineering phase in
which all the detailed engineering aspects and calculations are done.
 BACKGROUND
 This project deals with the design of a 36” onshore crude oil pipeline of length
5.775 km.
 This new pipeline is hot tapped from an existing line at ABC Manifold and
ends at XYZ refinery.
 The conceptual design and basic engineering were already done by the client
and were included in the tender for reference.
 The overall project deals with detailed engineering calculations and various
analysis on suitable engineering analysis software and to create detailed Excel
Worksheets for the same.
INITIAL DESIGN PARAMETERS
Outer Diameter (inch) 36 inch

Preliminary Minimum Wall 0.375 inch

Thickness(inch)

Design Temperature (oF) 200oF

Design Pressure (psig) 250 psig

Corrosion Allowance (inch) 0.11811 inch

Pipeline Material API 5L Grade - B (PSL-2) Spiral / LSAW

 OBJECTIVES
The main objective of the project is to do the following detailed engineering calculations
and analyses:
 Pipe wall thickness calculation
 Combined stress calculation and longitudinal stress calculation
 Minimum elastic bend radii calculation
 Bend thinning calculation
 Calculation for check for pipeline floatation in areas of high water table.
 Anchor force, Virtual anchor length and Free end expansion calculation.
 Calculation of minimum thickness for uncased road crossings.
 OBJECTIVES
 Calculation to check for upheaval buckling of pipeline due to temperature
and pressure.
 Hydraulic calculations.
 Hot tapping calculation.

The following analyses are also to be done on the pipeline:

 Hydraulic analysis on the pipeline using PIPENET V1.81 STD Model.

 Surge analysis on the pipeline using PIPENET V1.81 STD Model.
 Stress analysis on the pipeline using CAESAR II.
 METHODOLOGY
 The methodology followed for the design calculations are as per ANSI, ASME, OTC,
AWWA, BSI standard for liquid pipelines.
 Pipe wall thickness calculation: ASME B31.4, ASME B36.10
 Road crossing calculation: API 1102
 Combined stress calculation: ASME B31.4
 Elastic bend radii Calculation: ASME B31.4
 Bend thinning calculation: ASME B31.4, BSI PD 8010-1
 Floatation calculation: AWWA M9, AWWA M11
 Hot tapping calculation: SAEP 311, SAES L 150, ASME B31.4
 Upheaval buckling calculation: OTC 6335
 Free end expansion and Anchor Force Calculation: ASME B31.4
 WALL THICKNESS CALCULATION
ASME B31.4 is used to calculate the wall thickness of the pipeline.

The procedure used for calculating the wall thickness is as follows:

 Calculate wall thickness, tc as per ASME B31.4.

 Calculate wall thickness by taking into consideration the corrosion allowance, t ca.

 Select appropriate wall thickness from pipe chart, tw.

 Check the ratio of diameter over selected thickness, D/t w is greater than 100.
 Calculated Wall Thickness, tc
The below is a modified Barlow’s equation which includes design factor and weld joint factor. Wall
thickness is calculated from the following formula:

Where,
tc = calculated wall thickness in inch.
P = Design pressure of pipeline, psi.
D = Nominal diameter of pipeline in inch.
SMYS = Specified Minimum Yield Stress in psi.
F = Design Factor.
E = Weld Joint Factor.
 Wall Thickness with Allowance, tca

Thickness allowance, A, is the sum of the allowance for threading, grooving, corrosion,
and so forth. The wall thickness allowance for corrosion is not required if pipe and
components are protected against corrosion in accordance with the requirements and
procedures prescribed in Chapter VIII “Corrosion Control” of the B31.4 code. Wall
thickness with corrosion allowance is given by:

Where,
tca = thickness of pipeline with allowance in inch.
tc = calculated wall thickness in inch.
A = corrosion allowance in inch.
 Selected Wall Thickness, tw

Wall thickness is selected from ASME B36.10. Suitable thickness is selected

based on D/tw ratio.

D/tw ratio should be less than 100 as per clause 403.2.5 in ASME B31.4.

This would help in enhance handling capabilities.

 PIPELINE FLOATATION CALCULATION
 Burying pipelines beneath the natural water table creates unique problems and
challenges.
 During periods of saturation of the aquifer, pipeline segments may become
buoyant.
 This results in a net upward force on the pipeline segment that could be sufficient
to compromise the pipe’s integrity.
 Pipeline should be designed in such a way that floatation of the pipe does not
occur at any point of time.
 In order for this to happen, the total downward force acting on the pipeline should
be greater than the upward buoyant force.
 PROCEDURE
 Weight of Fusion Bonded Epoxy coating is calculated, W fbe.

 Weight of adhesive is calculated, Wad.

 Weight of polyethylene coating is calculated, W pe.

 Weight of steel per unit length is calculated, W.
 Total weight of pipeline when it is empty is obtained from the sum of above calculated weights, W te.
 Total weight of pipeline when it is carry some fluid is calculated, this gives the total operating weight,
Wto.

 Mass of displaced ground water is calculated, W gw.

 Factor of Safety against flotation is calculated for both Compacted (FOS bc) & Uncompacted (FOSbuc)
soil is calculated.
 Outside Diameter of Pipeline, OD

Outside diameter of pipeline (OD) is calculated taking into consideration the nominal diameter,
adhesive thickness and coating thickness.

Where,
OD = outside diameter in inch.
D = Nominal diameter of pipeline in inch.
t1 = Thickness of Fusion Bonded Epoxy Coating in inch.

t2 = Thickness of adhesive in inch.

t3 = Thickness of polyethylene coating in inch.

 Weight of coatings

The weight of the FBE coating can be calculated by: Where,

D = nominal diameter of pipeline in inch.
Wfbe = Weight of FBE coating in lb/in.
The weight of the adhesive can be calculated as:
Wad = Weight of adhesive coating in lb/in.

Wad = Weight of polyethylene coating in lb/in.

The polyethylene weight in the coating is given by:
ρfbe = density of FBE coating in lb/in3.

ρad = density of adhesive in lb/in3.

ρad = density of adhesive in lb/in3.

t1 = thickness of FBE coating in inch.

t2 = thickness of adhesive in inch.

t3 = thickness of polyethylene in inch.

 Weight of steel, total empty weight & total weight in Operation

The weight of steel per unit length of pipeline is

Where,
given by:
W= weight of steel in lb/in.

Total weight of Empty pipeline Wte = Weight of empty pipeline in lb/in.

Wto = Weight of operating pipeline in lb/in.

ρs= density of steel in lb/in3.

Total Weight of Pipeline in Operation:
ρc = density of crude in lb/in3.
d= inside diameter of pipeline in inch.
Mass of ground water displaced, Wgw

Where,
Wgw = weight of ground water in lb/in.
D = Nominal Diameter of pipeline in inch.
ρgw = Density of ground water, in lb/in3
 Factor of Safety

Where,
For calculating factor of safety for uncompacted backfill:
FOSbuc = factor of safety for uncompacted soil.

FOSbc = factor of safety for compacted soil.

SG = Specific gravity of soil.
For calculating factor of safety for compacted backfill:
ρbuc = Density of uncompacted backfill, in
lb/in3.
ρbc = Density of compacted backfill, in lb/in3.

Wgw = weight of ground water in lb/in.

H = Effective depth of cover in inch.
D = Nominal Diameter of pipeline in inch.
 RESULT & CONCLUSION
• From the wall thickness calculation, it is obtained to be 0.375 inch. This
value pertains to the D/tw ratio of ASME B31.4 (Para 403.2.5).

• In the case of Pipe floatation calculation, the factor of safety (FOS)

value less than 1.5 indicates that the pipeline is unstable under given
conditions and susceptible for floatation. It is obtained that the pipe has
a tendency to float when uncompacted backfill is used. This issue can
be solved using compacted backfill.
 WORKS TO BE COMPLETED
Detailed report making on:
 Hot Tapping Calculation.
 Uncased Road Crossing Calculation.
 Hydraulic Calculation.
 Combined Stress Check
 Anchor Force, Virtual Anchor Length and Free End Expansion Calculation.
 Upheaval Buckling Calculation.

Hydraulic analysis using Pipenet V1.81 STD Model

Surge analysis using Pipenet V1.81 STD Model
Stress analysis using CAESAR II
 REFERENCE
 ASME B31.4: Pipeline Transportation Systems for Liquids and Slurries.
 ASME B31.3: Process Piping
 AWWA M11: American Water Works Association, Guide for Design and
Installation of Steel pipes.
 AWWA M9: American Water Works Association, Guide for Design and
Installation of Concrete pipes.
 Pipe Stress Engineering by L.C. Peng and Alvin Peng.
THANK YOU!