Table Of ContentAQuickGuidetoPipelineEngineering
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SpacedEns–QGPipelineEngineering
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A Quick Guide to
Pipeline Engineering
D. Alkazraji
BEng,CEng,MIMechE
Series editor: Clifford Matthews
MatthewsEngineeringTrainingLimited
www.matthews-training.co.uk
CambridgeEngland
SpacedEns–QGPipelineEngineering
TypesetbyDataStandardsLtd,Frome,Somerset,UK
PublishedbyWoodheadPublishingLimited,AbingtonHall,Abington
CambridgeCB216AH,England
www.woodheadpublishing.com
and
MatthewsEngineeringTrainingLimited
www.matthews-training.co.uk
First published 2008, Woodhead Publishing Limited and Matthews
EngineeringTrainingLtd
#2008,D.Alkazraji
This book contains information obtained from authentic and highly
regarded sources. Reprinted material is quoted with permission, and
sources are indicated. Reasonable efforts have been made to publish
reliabledataandinformation,buttheauthorandthepublishercannot
assume responsibility for the validity of all materials. Neither the
author nor the publisher, nor anyone else associated with this
publication, shall be liable for any loss, damage or liability directly
orindirectlycausedorallegedtobecausedbythisbook.
Neitherthisbooknoranypartmaybereproducedortransmittedin
any form or by any means, electronic or mechanical, including
photocopying, microfilming and recording, or by any information
storage or retrieval system, without permission in writing from
WoodheadPublishingLimited.
The consent of Woodhead Publishing Limited does not extend to
copying for general distribution, for promotion, for creating new
works, or for resale. Specific permission must beobtainedin writing
fromWoodheadPublishingLimitedforsuchcopying.
Trademarknotice:Productorcorporatenamesmaybetrademarksor
registered trademarks, and are used only for identification and
explanation,withoutintenttoinfringe.
BritishLibraryCataloguinginPublicationData
AcataloguerecordforthisbookisavailablefromtheBritishLibrary.
ISBN978-1-84569-490-6 (book)
ISBN978-1-84569-491-3 (e-book)
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PrintedbyCromwellPressLtd,Trowbridge,Wiltshire,UK
CoverphotographsbyAnneandKeithNewton.
SpacedEns–QGPipelineEngineering
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The Quick Guide Series
TheQuickGuidedatabooksareintendedassimplified,easily
accessed references to a range of technical subjects. The
initial books in the series were published by The Institution
of Mechanical Engineers (Professional Engineering
Publishing Ltd),written bytheseries editorCliffMatthews.
Theseriesisnowbeingextendedtocoveranincreasingrange
oftechnical subjects byMatthewsEngineering Publishing.
The concept of the Matthews Quick Guides is to provide
condensed technical information on complex technical
subjects in a pocket book format. Coverage includes the
various regulations, codes and standards relevant to the
subject.Thesecanbedifficulttounderstandintheirfullform,
sotheQuickGuidestrytopickoutthekeypointsandexplain
them in straightforward terms. This of course means that
eachguidecanonlycoverthemainpointsofitssubject–itis
notalwayspossibletoexplaineverythingingreatdepth.For
thisreason,theQuickGuidesshouldonlybetakenasthat–a
quickguide–ratherthanadetailedtreatiseonthesubject.
Where subject matter has statutory significance, e.g.
statutory regulation and referenced technical codes and
standards, then these guides do not claim to be a full
interpretation of the statutory requirements. In reality, even
regulations themselves do not really have this full status –
many points can only be interpreted in a court of law. The
objective of the Quick Guides is therefore to provide
information that will add to the clarity of the picture rather
thanproducenew subjectmatterorinterpretationsthatwill
confuse youevenfurther.
Ifyouhaveanycommentsonthisbook,oryouhaveany
suggestions for other books you would like to see in the
Quick Guide series, contact us through our website:
www.QGpublishing.com
CliffMatthews
Series Editor
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Invitation to New Authors
IfyouhaveanideaforaQuickGuidebookandareinterested
inauthorship,weareinterestedinhearingfromyou.Youdo
not have to already be a published author (in fact we are
activelyinterestedinfindingnewunpublishedoneswithabit
of talent). Allweask isthat:
. you know your subject as well as (or even slightly better
than) othersin yourfield;
. youcanexplain itin simple terms;
. you have the tenacity to write 25000–30000 words (and
accompanyingfigures andtables).
Ifyoucanmeettheserequirements,thengetintouchandwe
will discuss with you the procedure for submitting your
proposal.Contact Cliff Matthewsat:
[email protected]
SpacedEns–QGPipelineEngineering
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Preface
Pipeline engineering is a large subject area covering a range
of topics. This book provides a handy reference guide on
both onshore and offshore pipeline engineering that engi-
neers and students will find useful. Basic principles such as
design, construction, operation and maintenance are dis-
cussedwiththeaimofbeingconciseandinformative.When
workinginthepipelineindustry,therearenumerouspipeline
codes and standards, calculation approaches and reference
materialthattheoperatormustunderstandinordertomake
accurateand informeddecisions.
The book is divided into a number of sections including
design, construction, risk assessment, pressure testing,
operation and maintenance, condition monitoring, decom-
missioning andpipeline industrydevelopments.Throughout
thisbook,alongsidethese basicprinciples, thereisreference
to the main standards and literature that are used in the
pipeline industry. These references are essential for further
information.Thebookprovidesengineersandstudentswith
up-to-dateandaccurateinformationoncurrentbestpractice
and the underlying principles of pipeline engineering. For
example, the engineer might need to know what the main
corrosion assessment approaches today are, what quantita-
tive risk assessment is or what methods are available for
permanentandtemporaryrepair. ThesearequestionsthatI
haveputtomyselfandthathavepromptedmetoproducea
quick guide covering the full life cycle of pipelines, both
onshoreandoffshore.
I would like to thank the following for their assistance in
producingthis book:
British StandardsInstitute (BSI)
American Petroleum Institute(API)
Institution ofGas Engineers andManagers (IGEM)
SpacedEns–QGPipelineEngineering
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AQuickGuidetoPipelineEngineering
American Societyof Mechanical Engineers (ASME)
Pipeline ResearchCommittee (PRCI)
Det NorskeVeritas (DNV)
RosenGroup
Advantica
AmeronBV
Corus Tubes EnergyBusiness
Elsevier
NACE International
Finally,onapersonalnoteIwouldliketothankSuzannefor
herhelpandCliffMatthewsforcheckingmydraftsandalso
for providing help and guidance on writing this ‘Quick
Guide’.
About the author
Working as a pipeline engineer, Duraid Alkazraji is a
chartered engineer currently providing training services to
Matthews Engineering Training. Duraid Alkazraji has
worked in the pipeline industry for a number of years,
having joined the BG group on their graduate development
programme, and then going on to work for Advantica, PII
andSaipem UK.
x
SpacedEns–QGPipelineEngineering
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Summary
Thisquickguidetopipelineengineeringcoversanumberof
subjects:
. The initial stage of pipeline design is conducted before any
workcommences ontheconstruction.Itisimportantthat
environmental and legal considerations are taken into
account, for instance an environmental impact assessment
shouldbecarriedouttosatisfyappropriateauthoritiesand
regulations.Detaileddesigncanthenbestarted.Firstly,the
diameterandinletpressurearedecideduponaccordingto
themaximumacceptablepressuredropalongthelengthof
the pipeline. This is calculated using appropriate flow
equations for gas or liquid flow. Other design parameters
will then follow, including choosing an appropriate wall
thickness,materialgradeandcoatingmethod.Finally,the
maximum allowable operating stress will be decided upon
accordingtothelocationofthepipelineroute.Codessuch
as ASME B31.4 and B31.8 provide maximum operating
stresslimits based onthe surroundingpopulation density.
. The next stage then looks at pipeline manufacture and
construction. Spools are manufactured using four main
methods, with each manufacturing method generally
varying in the pipe sizes available. These manufacturing
methods include seamless, electric resistance welding
(ERW), longitudinally submerged arc welding (LSAW)
and spiral submerged arc welding (SSAW). Construction
and land preparation stages must be started, which in the
caseofonshorepipelinesinvolvesaworkingcorridorbeing
created and a pipeline trench being dug to a depth of
approximately 1.1m. Inthe case of offshore pipelines, the
trench is prepared using a dredger. Finally, positioning of
thepipelinecanbedoneusingS-layandJ-laymethodsfor
offshore pipelines. Once the pipeline is in the trench, it
must be protected from corrosion using sacrificial or
impressedcurrent corrosionprotection systems.
SpacedEns–QGPipelineEngineering
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AQuickGuidetoPipelineEngineering
. Controlling the risks from failure is an important part of
any integrity and management strategy. Consequently,
regulatorybodiessuchastheHealthandSafetyExecutive
(HSE) within the UK and the Department of Transport
(DOT)withintheUnitedStatesensurethatthesemanage-
ment systems are in place. The two main risk assessment
approaches used throughout the pipeline industry include
quantitative andqualitative methods.
. Followingtheseearlierstages,thepipelineisreadytobegin
operation. Before the pipeline can be operated safely,
pipeline design codes require that it is pressure tested. A
general hydrotest is usually conducted to 1.5 times the
design pressure. The hydrotest will identify defects that
mayfail at the design pressure. Current best practice is to
utilize high-level pressure testing, which provides a
hydrotestsafety margin. The basic principle of this isthat
the higher the pressure test used, the smaller the defects
thatwill remain.
. There are numerous types of defect that may be found in
pipelines, such as internal corrosion, external corrosion,
laminations,stresscorrosioncracking(SCC),cracks,dents
and gouges. Consequently, it is important that pipeline
operators utilize the most appropriate inspection methods
available.Currently,themostwidelyusedmethodsinclude
magnetic and ultrasonic inspection tools, but specialist
inspection tools are available that can detect SCC,
channelling corrosionand seam weld defects.
. Ultimately, the engineer has to decide whether a pipeline
containingareporteddefectisfitfortheintendedpressure
or whether it needs repair. There are various defect
assessment approaches, all of which can be rather
confusing, such as ASME B31.G, simplified RSTRENG
andDNV-RP-F101,etc.Themainmethodsusedthrough-
out the industry have been summarized in this book,
including effective area methods, UTS-based corrosion
assessment, dent fatigue life estimation and how to assess
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