Lysark Dale 2010

Design of Gas Transport Systems
14 October 2010
Elin Kristin Dale ekrd@statoil.com
1-
Classification: Internal
2010-10-05
TPG4140 NATURGASS, NTNU
Design of gas transport systems

Part 1: Intro Transport Technology Gas/condensate fields- and infrastructure development System design of pipelines Design premises included examples Part 2: Design premises included examples continues Pipeline Pressure protection System design of multiphase pipelines
2-
2010-10-05
TPG4140 NATURGASS NTNU
Part 1
Intro Transport Technology
3-
Classification: Internal 2010-10-05 Photo credit: Manfred Jarisch / StatoilHydro
Transport Technology
Development of total transport solutions - from Reservoir to Market Responsible for Transport Technology in Statoil: Multiphase system and flow assurance (FA) Transport optimisation and system design (TS)
Our job is to secure and optimize transport of oil and gas in pipeline systems
4-
2010-10-05
Reservoir conditions
Transport System Design
Market
conditions
System definition (pipelines, stations, fluids transported, interfaces with upstream and downstream facilities etc.) Technical feasibility Hydraulic analysis Pipeline design data (ID, temperature, pressure, U-value, etc) Pipeline system diagram Principles for pressure control and pressure protection Operational window definition Process optimisation, design and de-bottlenecking Interface management (management and coordination of the engineering, procurement, construction and commissioning of the transport system)
PLEM
5-
2010-10-05
Pipeline network analysis

Hydraulic analysis (capacity, de-bottlenecking, hydraulic optimization etc.) Gas quality analysis and management. Optimisation of flow in pipeline network wrt capacity and gas quality management. Evaluation and optimization of flexibility in gas network wrt capacity and gas quality management. Identification of bottlenecks in transport systems. Identification of measures for de-bottlenecking. Evaluation of business potential for new infrastructure etc. Booking support. Gas chain regularity analysis.
6-
2010-10-05
Operational support
Supervision, consultation and daily operation of leak detection system (PM-vakt) for Statoil operated pipelines. Other support to Pipeline Operations department: Hydraulic analysis Pigging procedures Operational manual Assessment of leakage detection Etc.
Mongstad Sture Kollsnes
Krst
7-
2010-10-05
Gas/condensate fields- and infrastructure development
8-
2010-10-05
Gas transport technology

50
Volume
BCM
20 10 5
CNG
(North sea)
PIPELINE
(Barents sea)
Floating LNG
LNG
GTL/Methanol
2 1 .50
Electricity
(HVDC)
UNECONOMIC
1000
2000
3000
4000
5000
Distance to market - Km
9Classification: Internal 2010-10-05
Transport analysis
New fields:
Volume profiles Type gas Profitability Geography Owners
Transport Solutions
Cost estimation
Economical analyse
NPV IRR Profit index Investment equivalent 7% after tax.
Infrastructure
Spare capacity Liquid recov. Tariffs Owners
Distance CAPEX Capacity OPEX Tie-ins Processing Liquid recov.. CO2 removal
Overall evaluation
SDA/SA economy Strategic fit Stakeholders Flexibility
Market:
Supply situation Geography Pricing
10 - Classification: Internal
2010-10-05
The Norwegian Continental Shelf

Statoil has developed the worlds largest offshore gas pipeline network Technical services are provided by Statoil for the world's most extensive submarine gas pipeline system: 7800 km pipelines (30 44) Long term transport capacity approx. 365 MSm3/d Statoil is the leader in the construction of large-diameter pipelines in deep water. On 1st January 2002, Gassco became the operator for most of the gas pipeline systems from the Norwegian continental shelf. On 1st January 2003, Gassled became the owner for most of the gas pipeline systems (Statoil share 32.055%, Statoil+Petoro share 72 %).
11 - Classification: Internal 2010-10-05
Gas/condensate fields- and infrastructure development Gas supply

Production profile Build-up and plateau level Market scenarios Volume Market opportunities (and flexibility) Company based sales Existing infrastructure Platforms Tie-ins and functional requirements Pipelines Capacity and ullage New infrastructure requirements
Existing infrastructure - capacity

The pipeline between X and Y is the main link between the production at A and B and the terminal E. Utilisation of the XY link affects the capacity towards E, creating a bottleneck and a gap between the actual delivery and the demand. Routing of the gas will determine the possible transportation capacity at a given scenario. The sum of exit capacity in a transport system is not necessarily equal the actual transport capacity. Transport capacity is dependent on volume scenario, bottlenecks and dependencies.
A
14,7 20
B
20 10
19,7
Y 49,7
15
Gap: ~15
Production scenario 1 [MSm3/d] Producers
Exit terminals C 10 D 15 E 65
A 30
B 40
2010-10-05
Overall field architecture Luva case

Example of business case: New field discovery Luva 20-30 MSm3/d, 300 km offshore, 1300 meter depth, lean gas and some condensate Which field architecture will you recommend to your management ? Some of the parameters to be evaluated :
Luva Norne,
Ormen (1000m)
Nyhamna
Technical: Choice of installation (floater, fixed structure), mooring system, store or transport, processing, naval architecture, sensitivity to weather/sea conditions (hurricane, ice bergs, waves, tide, temperature etc), fluid properties (wax, hydrates, corrosion etc.), pigging, ship transport path, design codes, infrastructure (helicopter base, logistics, storage equipment/fluids, accommodation Economic analyses: availability in marked, location of construction, rent or own, distance from field to market, pipeline transport fee, country laws and regulations, personnel availability, company philosophy
2010-10-05
Pipeline system design Terms and definitions
2010-10-05
Pipeline system design terms and definitions

Pipeline system A pipeline with compressors or pump stations Pressure reduction stations Metering Tankage Supervisory control and data acquisition system (SCADA) Safety systems Corrosion protection systems And other equipment, facility or building used in the transportation of fluids Pipeline Those facilities through which fluids are conveyed, including pipe, pig traps, components and appurtenances, up to and including the isolation valve.
Petroleum and natural gas industries Pipeline transportation systems, ISO 13623
Pipeline system design system definition

The extent of the pipeline system, its functional requirements and applicable legislation should be defined and documented. The extent of the system should be defined by describing the system, including the facilities with their general locations and demarcations and interfaces with other facilities. The functional requirements should define the required design life and design conditions. Foreseeable normal, extreme and shut-in operating conditions with their possible ranges in flow rates, pressures, temperatures, fluid compositions and fluid qualities should be identified and considered when defining the design conditions.
Petroleum and natural gas industries Pipeline transportation systems, ISO 13623
OS F-101: Submarine Pipeline Systems
2010-10-05
" I draw lines, I don't move trees"

Pipeline systems
Subsea Production Systems (ISO 13628) and Pipeline Transportation Systems (ISO 13623)
ESV
Platform/Floater
PIG TRAP
SUBSEA PROCESSING UNIT
ESV
PIG TRAP
Subsea Production
MANIFOLD X-MAS TREE CHOKE PWV PMV
Subsea isolation
SSIV
HIPPS
BRANCH
RISER BASE SSIV CHECK
CHOKE TEMPLATE AND MODULE MANIFOLD SCSSV
Onshore
LANDFALL ESV TEE PIG TRAP
Subsea connection Single phase; Gas, Oil, condensate CHECK + BLOCK Multiphase;
PLEM
Pipeline Systems:
2010-10-05
Pipeline system design work process

Thermohydraulic analysis Functional requirements; gas routing, regularity, gas quality, agreements Overall Operational Philosophy; Control and Safety System, Environment, etc. Control and Safety Philosophy System design concept
Internal diameter, capacity, pressure and temperature profile, etc.
Functional requirements, Regularity, Deliverability
Pipeline System Diagram, Process Flow Diagram
P&IDs QA Boundary conditions and technical interface between platform pipeline terminal
2010-10-05
Pipeline Project Organisation (Typical)

Project Manager
Project Control
Authority
Procurement
HSE
Upstream Platform/Terminal Administration EIA
Downstream Platform/Terminal
Pipeline Engineering
System/RFO
Pipeline Construction
Landfall
Preparation for Operation
2010-10-05
Design premises
2010-10-05
Pipeline system design Design premises 1/3

Area B - sgard Transport, Krst temp.
High Rough
5
Likely Rough
Low Rough
Temperature, C
Pipeline Route Length Bathymetric profile Environmental Conditions Air temperature Sea bottom temperature Ground temperature Geo-technical data (soil conditions)
-1
-3 66 68 70 72 74 76 78 80 82 84 86 Hydraulic capacity, MSm/d
Area B - sgard Transport, Krst pressure

High Rough 130 125 Pressure, barg 120 115 110 105 100 95 90 85 80 66 68 70 72 74 76 78 80 82 84 86 Hydraulic capacity, MSm/d Likely Rough Low Rough
2010-10-05

Pipeline Data Design pressure Design temperature Internal diameter Wall thickness Internal coating Concrete coating Insulation Trenching/dredging Gravel/rock dumping
2010-10-05
Langeled Bredero Shaw i Farsund Sept. 2004

Concrete coating (330 000 m3) = 1,5 Troll A GBS Total pipeline steel (962 000 t) = 40 Troll A deck Coating (25 000 t) = 3 Eiffel Towers Total coating wire: (51 900km) = 1.3 times around the equator
1200 km a 12m pipes:
Per pipe: Ca 25 tonns
2010-10-05
The largest laying vessels

Solitaire: The worlds largest pipeline laying vessel at Nyhamna
Acergy Piper: At Sleipner T at start-up of the laying process
2010-10-05

Gas properties Equation of state Gas composition Friction equation Internal roughness Transport specification Sales gas specifications Pressure Control System Pressure regulating Pressure safety Pig trap arrangement Pigging philosophy Pipeline valve philosophy Future requirements
2010-10-05
Transport of 42 subsea pipeline valve
Double expanding gate Weight of valve: 80 tons (60 cars..) 10m high including activator: Total of 100 tons
2010-10-05
Part 2 Design premises Hydraulic capacity and gas quality

29 - Classification: Internal 2010-10-05 Photo credit: Manfred Jarisch / StatoilHydro
Photo credit: Helge Hansen, Statoil
Hydraulic capacity Sensitivity analysis

Variation of parameters and hydraulic capacity compared to basis Zeebrugge 69.5 MSm/d (october) 5 Trenching -200 Km
Length +/-10 Km 4
Temperature
10 micron
Roughness 1- 3 micron
1 -2 -1.5 -1 -0.5 0
Gas Composition
0.5
1.5
2.5
2010-10-05
Pipeline system design Hydraulic analysis 1/2

The objective of the system design develop overall transport solutions for the gas chain from the field to the market which will maximize the value of the liquid- and gas products and without any unreasonable external conditions for any third party (fields or transport systems).
deliver gas quantities nominated by the buyers within the desired quality specifications.
ensure high availability and regularity within reasonable technical and economical limits and relevant agreements.
2010-10-05
Pipeline system design Hydraulic analysis 2/2

The hydraulics of the pipeline system should be analysed to demonstrate that the system can safely transport the fluids for the design conditions specified by the system definition, and to identify and determine the constraints and requirements for its operation. This analysis should cover steady-state and transient operating conditions. Describe the function loads for the pipeline design Pressure profile Temperature profile Density profile (fluid) Velocity profile Design cases: Normal operation, start-up, planned shut-down, etc. Not planned operation, emergency shut-down, depressurisation, etc. Emergency preparedness analysis; accidents, pipe rupture, leakage etc.
2010-10-05
Why gas quality specifications?

Ensure interoperability /interchangeability WI Ensure unproblematic transport of gas Max/min temperature and pressure Prevent corrosion and erosion of equipment Water, CO2, H2S content Prevent condensation of liquid HC dew point Prevent gas hydrates Water dew point
2010-10-05
Hydrates main reason for temperature control in multiphase pipelines

Kristin hydrate curve
900 800 700
Pressure, bar
Potensial for hydrate formation
600 500 400 300 200 100 0 0 5 10 15 20
Safe operating conditions
Temperature, C
25
30
35
2010-10-05
Pipeline system design Gas quality

To avoid deposits in a pipeline and to minimise the possibility of any kind of corrosion, including internal stress corrosion, it is essential that the gas should conform to the following: The water dew-point, at the working pressure, should at all times be below the temperatures of the pipeline. The hydrocarbon dew-point, at the working pressure, should at all times be below the temperature of the pipeline this will also ensure that the calorific value of the gas is not reduced by condensation of hydrocarbons. It should be dust-free.
Hydrocarbon dew-point (-3 C, 69 barg) Water dew-point (-12 C, 69 barg) CO2 content (max 2.5 % mol) H2S content (5 mg/Nm3) GCV (Gross calorific value) Wobbe index (WI) Max/min pressure and temperature
System description battery limits

Kollsnes Export Facilities
IJ Kp 0
Anchor Block
Tie-in spool 42/44 Kp 0,15 Tunnel Kp 1,19
Offshore
B.L
KP xx
Beach/Breakwater Kp 0 IJ
RF Fence
Offshore
RFO Tie-in 44 spool Landfall Spool LVS 44/42 42 onshore incl. Road, railway, & Canal Crossing
IJ Receiving Facilities (RF)
Near shore
ESDV & PRF
Export line
2010-10-05
Kollsnes Overview
el unn PT KG
KN Tunnel
nne E Tu GN
l
n Tun KS el e unn ST KS l
2010-10-05
Zeebrugge Landfall
2010-10-05
Kollsnes tunnel movie
2010-10-05
Multi design pressure concept

Normal Design
PD
Low utilisation of pipe material
Multi Design Pressure

PD1 PD2
Settle out pressure
PD3
Normal pressure profile Upstream end Downstream end
Normal pressure profile
Base Case GNE PD=203 barg

Test=1.05*MIP MIP=1.05*PD Test=1.05*MIP MIP=1.10*PD Settle out pressure
The settle out pressure in a normal shut-in situation shall not exceed the lower design pressure The pipeline hydraulics during normal, upset and packing conditions are analysed to demonstrate that the pressure control and pressure protection system will act satisfactory Cost saving material
PD=156.8 barg
Normal pressure profile
2010-10-05
Shut down of receiving facility Kollsnes export is stopped 0.5 hour later
44" Den Helder. SOP at 2% Opflex. October
0 210 200 190 180 Kollsnes 170 160 150 140 130 120 110 100 90 0 100
Norwegian sector Danish sector German sector Dutch sector
Time, hrs 8 10
12
14
16
18
203 barg (+10m)
Pressure, barg
156.8 barg (+10m)
Den Helder
200
300
400 500 Distance, km
600
700
800
900
2010-10-05
NCS Gas transport system

More than 7800 km oil and gas pipelines with diameter up to 44 5 pipelines with multi design pressure concept
Gas pipeline system Statpipe Zeepipe Europipe Troll gas Zeepipe II Haltenpipe Franpipe Europipe II sgard Transp Heidrun/Norne Huldra gas Kvitebjrn gas Langeled Oper. Year 1985 1993 1995 1996 1996 1996 1998 1999 2000 2001 2001 2004 2006 2007 Size each leg, inch 28, 30, 36, 36 30, 40 40 36, 36 40, 40 16 42 42 42 16 22 30 44 42 Length km 880 850 670 130 610 250 840 660 700 200 150 145 1200 Depth m 300 80 70 360 370 360 70 300 370 350 125 350 350
2010-10-05
Pressure protection
2010-10-05
Pressure protection of gas export pipelines

This should be simple!? Close inlet valve and separate the source from the pipeline.!?
Pipeline In Out
2010-10-05
Pipeline pressure protection

Triple redundant Fiberoptic and telemetry
PPS-1
PPS-2
PPS-1
PPS-2
PT PT
EV
EV
PT PT
Pipeline Upstream Plant Downstream Plant
2010-10-05
Risk reduction
Allocations of risk reducing measures
Achieved freq of overpressure
Acceptable risk (Frequency of overpressure ) 1x10

-5
Frequency of overpressure Without risk reduction 1 times pr year Required risk reduction
Frequency of overpressure
Facilities regulation 33 ISO 10418 (API 14 C) IEC 61508 IEC 61511
Actual risk reduction Manuel actions
PPS -2
PPS -1
PPC
Achieved risk reduction from safety functions PPC: Independent of the PSS PPS: Two independent systems activated at different pressure levels, and with a redundant and fail safe instrumentation and signal transfer system
2010-10-05
Pipeline pressure control & protection

Kollsnes
PPS Telemetry
Receiving Facility
PPS Telemetry
Triple redundant
PPS1 PPS2
PCDA/MPC
PPS1
PPS2
PPC (PCDA)
Telemetry
Pressure, Flow rate, valve position
P T
P T
Pipelin e
LV S
P T
P T
The PPC shall ensure that the pressure is below the pipeline local design pressure during normal operations The PPS shall ensure that the pressure is below the pipeline local Incidental pressure
PPC: Compressor control based on pressure, flow rate, valve status PPS1: Pipeline Protection System Level 1- shut down of 2 valves, set pressures Kollsnes and RF PPS2: Pipeline Protection System Level 1- shut down of 2(ESV) valve, Set pressures Kollsnes and RF
Typical onshore receiving terminal

PIG TRAP 3 PROCESS TRAINS FOR PRESSURE AND TEMPERATURE CONTROL FISCAL METERING GAS FIRED HEATER
PIG TRAP GAZ DE FRANCE
Dunkerque, France
2010-10-05
System Design - Heating

During operation of the pipeline system the minimum design temperature may be violated due to high utilisation of the system or high pressure gradients in parts of the system (Joule-Thomson effect). In normal operation, heating of the gas may be required to avoid that the temperature drop below the minimum design temperature or other limitations (sales agreements). In upset situations the pressure build-up in parts of the system may cause the temperature to drop below the minimum design temperature. Heating of the gas may therefore be required in order to avoid the minimum temperature to be violated.
2010-10-05
Heating requirements
Steady state simulations. Terminal temperature= 2C (March)
Pipeline studio: Steady-state simulations Capacity Arrival Pressure barg 80 90 100 110 120 130 140 Pin 201barg Arrival temp. C -4.63 -2.87 -1.34 -0.01 1.12 2.07 2.85 Terminal @80barg hx - MW 12.520 17.530 22.100 26.010 29.120 31.320 32.700 Terminal @75barg hx - MW 16.790 21.550 26.120 29.790 32.650 34.860 35.990 Terminal @70barg hx - MW 21.060 25.960 30.150 33.820 36.430 38.400 39.290 Terminal @65barg hx - MW 25.330 30.230 Hysys
Required heating duty at maximum packing Terminal @80barg Terminal @70barg Capacity@201barg Terminal @75barg Terminal @65barg
90 80 70
Duty (MW)
90 80 60 50 40 30 20 10 90 100 110 120 130 0 140

Hydraulic Capacity (MSm/d)
MSm3/d 71.19 69.33 67.17 64.67 61.8 58.53 54.77
70
60 50 40 30 20 10 0 80
34.170 37.600 40.220 41.930 42.580
TIC PIC PT TT
RF Arrival pressure (barg)

PV
2010-10-05
Zeebrugge RF: Heater duty and Volume losses

Start-up flow rate vs. time for Terminal@65 barg and 2C
Start-up capacity for 40 and 30 MW
70 65 Start-up capacity, MSm/d 60 55 50 45 40 35 30
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000
3.5 MSm 80 MSm
Duty 40MW Duty 30MW
Time from start-up, min
2010-10-05
System design of multiphase pipelines
2010-10-05
The diameter dilemma of long gas-condensate pipelines

Technical feasibility for how long can reservoir drive production to shore?
Minimize pressure drop
large pipe diameter
Operational acceptability will system availability be high enough?

Minimize liquid inventory in pipeline Design rate Large ID Liquid content (m3)
small pipe diameter Design rate

8000 7000 6000 5000 4000 3000 2000 1000 0 24 26 28 30 32 34
50
Pressure drop (bara)
Large ID
40
30
Small ID
20 20 22 24 26 28 30 32 34
Small ID
Gas rate (MSm3/d)
Gas rate
(MSm3/d)
2010-10-05
Conventional design of gas-condensate pipelines

Pipeline diameter: small Minimize liquid inventory Accept moderate/high pressure drop Rate increase: From maximum turndown to design rate Pigging Pressure drop (bara)
50
Troll slug-catcher
Slug-catcher
8000
Slug-catcher size set by:
Liquid inventory prior to pigging Liquid content (m3)
7000 6000 5000 4000 3000 2000 1000 0 24 26 28 30 32 34
volume
40
Design pressure drop Maximum turndown Design rate
Maximum turndown
Steady state liquid content
30
Design rate
20 20
22
24
26
28
30
32
34
Gas rate
(MSm3/d)
Gas rate
(MSm3/d)
2010-10-05
Pressure drop (bara)
New design of gas-condensate pipelines

Pipeline diameter: large Minimize pressure drop Accept relatively large liquid inventory If possible, alleviate liquid load Multi-diameter pipelines/dual lines Exploit pipelines slow response to transients Operational procedures Slug-catcher design Exploit pipelines slow response to transients Reduce slug-catcher size Onshore reception system routes liquid to off-spec tank Optimise slug-catcher design
50 40
Large ID
30
20 20
Small ID
22 24 26 28 30 32 34
Gas rate Volume rate (m3/h)

300 200 100 0
(MSm3/d)
Liquid flow into slug-catcher
6 8 10 Time (days)
12
14
2010-10-05
Kay learning points

Complexity of field architecture development Parameters influencing pipeline infrastructure development Pipeline design premises How the hydraulic of the pipeline system influence pipeline design Pressure protection of pipeline systems Functionalities of pipeline system components
2010-10-05
Thank you
Design of gas transport systems Elin Kristin Dale Senior engineer Transport Analysis ekrd@statoil.com , tel: +47 99 15 73 34 www.statoil.com
2010-10-05

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Design of Gas Transport Systems

Elin Kristin Dale ekrd@statoil.com

TPG4140 NATURGASS, NTNU

Design of gas transport systems

TPG4140 NATURGASS NTNU

Classification: Internal 2010-10-05 Photo credit: Manfred Jarisch / StatoilHydro

TPG4140 NATURGASS NTNU

TPG4140 NATURGASS NTNU

Transport System Design

TPG4140 NATURGASS NTNU

Pipeline network analysis

TPG4140 NATURGASS NTNU

Mongstad Sture Kollsnes

TPG4140 NATURGASS NTNU

Gas/condensate fields- and infrastructure development

Gas transport technology

TPG4140 NATURGASS NTNU

TPG4140 NATURGASS NTNU

The Norwegian Continental Shelf

TPG4140 NATURGASS NTNU

Gas/condensate fields- and infrastructure development Gas supply

TPG4140 NATURGASS NTNU

Existing infrastructure - capacity

TPG4140 NATURGASS NTNU

Overall field architecture Luva case

TPG4140 NATURGASS NTNU

Pipeline system design Terms and definitions

Pipeline system design terms and definitions

TPG4140 NATURGASS NTNU

Pipeline system design system definition

OS F-101: Submarine Pipeline Systems

TPG4140 NATURGASS NTNU

" I draw lines, I don't move trees"

TPG4140 NATURGASS NTNU

SUBSEA PROCESSING UNIT

RISER BASE SSIV CHECK

CHOKE TEMPLATE AND MODULE MANIFOLD SCSSV

TPG4140 NATURGASS NTNU

Pipeline system design work process

Internal diameter, capacity, pressure and temperature profile, etc.

Functional requirements, Regularity, Deliverability

Pipeline System Diagram, Process Flow Diagram

TPG4140 NATURGASS NTNU

Pipeline Project Organisation (Typical)

Upstream Platform/Terminal Administration EIA

Preparation for Operation

TPG4140 NATURGASS NTNU

Pipeline system design Design premises 1/3

-3 66 68 70 72 74 76 78 80 82 84 86 Hydraulic capacity, MSm/d

Area B - sgard Transport, Krst pressure

TPG4140 NATURGASS NTNU

Pipeline system design Design premises 2/3

TPG4140 NATURGASS NTNU

Langeled Bredero Shaw i Farsund Sept. 2004

1200 km a 12m pipes:

Per pipe: Ca 25 tonns

TPG4140 NATURGASS NTNU

The largest laying vessels

Acergy Piper: At Sleipner T at start-up of the laying process

TPG4140 NATURGASS NTNU

Pipeline system design Design premises 3/3

TPG4140 NATURGASS NTNU