Surface Production Operations: Volume III: Facility Piping and Pipeline Systems

Maurice Stewart

• Publisher: Gulf Professional Publishing
• Year: 2015
• Print ISBN: 9781856178082
• eBook ISBN: 9780080964218
• Topic: Technology & Engineering
• Subtopic: Civil Engineering
• Index: Technology & Engineering

Surface Production Operations: Facility Piping and Pipeline Systems, Volume III is a hands-on manual for applying mechanical and physical principles to all phases of facility piping and pipeline system design, construction, and operation. For over twenty years this now classic series has taken the guesswork out of the design, selection, specification, installation, operation, testing, and trouble-shooting of surface production equipment.The third volume presents readers with a "hands-on" manual for applying mechanical and physical principles to all phases of facility piping and pipeline system design, construction, and operation. Packed with charts, tables, and diagrams, this authoritative book provides practicing engineer and senior field personnel with a quick but rigorous exposition of piping and pipeline theory, fundamentals, and application.Included is expert advice for determining phase states and their impact on the operating conditions of facility piping and pipeline systems; determining pressure drop and wall thickness; and optimizing line size for gas, liquid, and two-phase lines. Also included are a guide to applying international design codes and standards, and guidance on how to select the appropriate ANSI/API pressure-temperature ratings for pipe flanges, valves, and fittings.- Covers new and existing piping systems including concepts for expansion, supports, manifolds, pigging, and insulation requirements- Presents design principles for a pipeline pigging system- Teaches how to detect, monitor, and control pipeline corrosion- Reviews onshore and offshore safety and environmental practices- Discusses how to evaluate mechanical integrity

1

Overview of facility piping and pipeline systems

Abstract

This chapter introduces the reader to process plant piping and pipeline systems design. At the outset, one must ask the following questions: What fluids are conveyed?, What do we want to do with the fluid?, How will we do what?, What materials, size, and thickness are required?, What is the layout?, and How will the piping be supported? Final design emerges from familiarity with piping and pipeline systems, equipment, instrumentation, plan design, and related disciplines.

Once fluid properties and general piping system components are identified, the next step is to design the facility that includes defining facility layout, developing engineering drawings, and specifying the facility piping and pipeline systems. With the ever-increasing amount of the world’s crude oil and gas coming from offshore fields, a growing amount of engineering effort is being expended on offshore facility designs. Therefore, a brief discussion of platforms that accommodate simultaneous drilling and production operations are discussed.

Keywords

Fluid characteristics

Flowlines

Trunklines

Manifolds

Production header (and/or test header)

Gathering system

Separation station

Compressor station

Pumping station

Production facility

Facility (on-plot) interconnecting piping

Transmission line

Injection system

Facility concept

Block diagram

Process flow diagram

Piping and instrumentation diagram (P&IDs)

Plot plan

Design and analysis

Isometric drawings

1.1 Overview

After wells are successfully drilled and completed, the fluid produced must be transported to a facility where it separated into oil, water, and gas; conditioned to meet process input requirements; treated to remove impurities such as H₂S, CO₂, H₂O, and solids; processed into specific end products, for example, NGL and LPG; measured; and refined or stored for eventual sales. Figure 1.1 is a simplified block diagram that illustrates the basic “wellhead to sales” concept. The diagram begins with wellhead choke which is used to control the rate of flow from each well. The fluid from the well travels through a flowline to the production facility where the fluid is separated, conditioned, treated, processed, measured, refined, or stored. Detailed discussions concerning oil, gas and water handling, conditioning, and processing facilities are covered in Volumes 1 and 2; pumps, compressors, and drivers are covered in Volume 4; and sizing, selecting, designing, installing, and operating process equipment-pressure vessels, heat exchangers, and storage tanks are covered in Volume 5.

Figure 1.1 Block diagram of “wellhead to sales” concept.

Volume 1: Design of Oil-Handling Systems and Facilities and Volume 2: Design of Gas-Handling Systems and Facilities of the Surface Production Operations series present the basic concepts and techniques necessary to select, specify, size, operate, and troubleshoot oil, water and gas handling, conditioning, and processing facilities. Volume 3: Facility Piping and Pipeline Systems builds upon the information that is presented in Volumes 1 and 2.

Chapter 1 provides an introduction of piping design and projects, types and functions of facility and pipeline systems and facility design considerations. The Chapter also reviews a typical facility piping design project and reviews specific considerations related to offshore operations. Chapter 2 reviews piping standards, codes, and recommended practices for both facility piping and pipeline systems. This chapter discusses both ASME and other international piping standards. Chapter 3 reviews ASME Piping Code material requirements for ferrous, nonferrous, and plastic pipe. High- and low-temperature service material requirements and insulating materials are also discussed. Chapter 4 covers piping system components such as the various methods of connecting pipe, expansion joints and flexible piping, fittings, valves, valve specifications, and pressure ratings. Engineering drawings, data sheets, piping drafting symbols, and flow plan arrangement are discussed in Chapter 5. Chapter 6 discusses fluid flow and pressure drop determination, while Chapter 7 discusses the parameters that need to be considered when choosing a line size and code requirements when determining the wall thickness. Chapter 8 covers relief device selection, sizing, installation and relief, and vent and flare disposal system design. Facility piping system design, piping details, layout, supports, and vessel and piping equipment are covered in Chapter 9. Chapter 10 discusses expansion piping and flexibility considerations. Chapter 11 reviews all phases of both onshore and offshore pipeline engineering, pipeline mechanical design, pipeline construction considerations, and unique offshore pipeline considerations. Chapter 12 discusses facility piping and pipeline system pressure testing and nondestruction examination requirements. Chapter 13 discusses reasons for pigging a pipeline, designing a pipeline for pigging, pig traps and pigging stations, pig types and uses, and in-line inspection tools. Pipeline operations, integrity assessment, and pipeline emergencies and repairs are covered in Chapter 14.

1.2 Introduction to piping design and projects

There are many commercial and industrial fluid handling applications conveying fluid from one location to another. At the outset, one must ask the following questions:

• What fluids must be conveyed?

Oil, wat...

Table of contents

• Cover image
• Title page
• Table of Contents
• Copyright
• Dedication
• Preface
• Acknowledgments
• 1: Overview of facility piping and pipeline systems
• 2: Piping standards, codes, and recommended practices
• 3: Material requirements: Piping materials
• 4: Piping system components
• 5: Engineering drawings: data sheets and symbols
• 6: Fluid flow and pressure drop
• 7: Choosing a line size and wall thickness
• 8: Relief, vent and flare disposal systems
• 9: Piping system design: Layout, supports, and piping vessels and equipment
• 10: Pipe expansion and flexibility
• 11: Pipeline systems
• 12: Pressure testing and nondestructive examination
• 13: Pipeline pigging
• 14: Pipeline operations
• Appendix 1
• Appendix 2
• Appendices 3A–3G
• Appendix 4
• Appendix 5
• Appendix 6
• Appendix 7
• Appendix 8
• Appendix 9
• Appendix 10
• Appendix 11
• Appendix 12
• Appendix 13
• Appendix 14
• Index