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GASLINE SP XI – SKG II PROJECT JOB No: 001 PT. PERTAMINA EP – FIELD

GASLINE SP XI SKG II PROJECT

JOB No: 001

PT. PERTAMINA EP FIELD LIMAU

BASIS OF DESIGN - PIPELINE SYSTEM

DOCUMENT NUMBER: 002/2014-LMU-001

REV

REV

DESCRIPTION

PREP’D

CHK’D

APP’D

NOTE

A 00

ISSUED FOR CONSTRUCTION

AS

B 00

ISSUED FOR INTERNAL REVIEW

AS

GASLINE SP XI – SKG II PROJECT PT. PERTAMINA EP – FIELD LIMAU

GASLINE SP XI SKG II PROJECT PT. PERTAMINA EP FIELD LIMAU

BASIS OF DESIGN - PIPELINE SYSTEM

TABLE OF CONTENTS

 

Page

1.0

SCOPE

3

2.0

CODES, STANDARDS AND SPECIFICATIONS

3

3.0

GENERAL REQUIREMENTS

3

4.0

SYSTEM DESCRIPTION

3

5.0

DESIGN REQUIREMENTS

5

6.0

DESIGN DATA

7

7.0

DOCUMENTATION

9

GASLINE SP XI – SKG II PROJECT PT. PERTAMINA EP – FIELD LIMAU

GASLINE SP XI SKG II PROJECT PT. PERTAMINA EP FIELD LIMAU

1.0

SCOPE

This document covers the Basis of Design for the Gasline SP XI SKG II Project for the detailed design of onshore pipelines.

2.0

CODES, STANDARDS AND SPECIFICATIONS

The requirements and recommendations of the latest revisions of the following listed codes, standards and Specifications shall apply:

2.1 Codes

AGA

On Bottom Stability Software

API RP 1102

Steel Pipelines Crossing Railroads and Highways

API Spec 5L

Specification for Line Pipe

ASME B31.4

Liquid Petroleum Transportation Piping Systems

ASME B31.8

Gas Transmission and Distribution Piping Systems

2.2 Project Documents

003/2014-LMU-001 Pipeline Material Specification

004/2014-LMU-001 Pipeline Installation Specification

005/2014-LMU-001 Pipeline Protective Coatings Specification

006/2014-LMU-001 Cathodic Protection Pipeline Specification

007/2014-LMU-001 Pig Launcher-Receiver Pipeline Specification

3.0

GENERAL REQUIREMENTS

The purpose of this Basis of Design and its referenced codes, standards and Specifications is to establish a minimum level of acceptable quality. Alternate standard designs of equal or superior quality may be proposed, provided all exceptions are listed and written approval for all exceptions is obtained from COMPANY.

In the case of conflict between documents, CONTRACTOR shall submit the discrepancy immediately to COMPANY for final resolution.

The pipelines will be designed and constructed according to ASME B31.8.

Project specific design criteria shall be submitted to COMPANY for approval prior to the start of detail engineering.

4.0

SYSTEM DESCRIPTION

4.1 Description

The pipeline system for the Gasline SP XI SKG II Project comprises the following components:

12 inch tie-in from SP XI into the proposed SKG II Low Pressure Scrubber and Pig Receiver.

12 inch tie-in from SP XI into the proposed SP XI Discharge Compressor and Pig Launcher.

GASLINE SP XI – SKG II PROJECT PT. PERTAMINA EP – FIELD LIMAU 4.2 12

GASLINE SP XI SKG II PROJECT PT. PERTAMINA EP FIELD LIMAU

4.2 12 inch tie-in from SP XI into the proposed SKG II Low Pressure Scrubber and Pig Receiver

The proposed line from SP XI into the proposed SKG II Low Pressure Scrubber will initially be used to supply gas from SP XI to SKG II. It is intended that as part of gasline project will be split into two sections. The first section will run from SP XI to SKG II Low Pressure Scrubber, and will supply gas to SKG II, replacing pipeline 12 inch existing for single line supply gas from SP XI to SKG II. The second section will run from gasline to pig receiver in SKG II, and will transport liquids from SP XI to SKG II for pipeline cleaning process.

The pipeline will be installed and tested by Contractor with a dummy flanged spool adjacent in SKG II Low Pressure Scrubber and Pipeline in SKG II Pig Receiver. The spool will be removed as part of this Project to split the pipeline into two sections, and two points tie-ins will be installed. One to tie-in the gasline SP XI - SKG II into the SKG II Low Pressure Scrubber section of the pipeline, and the other to tie-in the Pig Receiver section in SKG II.

The tie-ins shall be installed using the same line pipe. Pipeline wall thickness, coatings, and concrete weight coat will be the same as for existing pipeline. Spare 12 inch line pipe procured via this project by COMPANY shall be responsible for pre-formed bends (if needed), flanges and their fittings, and the associated coatings of the spools.

The tie-ins shall be routed to avoid possible conflicts with pipeline existing and pipeline of Pig Receiver. The routing must also allow space for the proposed future pipeline tie-ins from another gathering station.

The SP XI - SKG II pipeline shall be isolated prior to the tie-in. A remote controlled mechanical isolation plug or similar equipment approved by COMPANY shall be set into position just past a removable spool.

After hydrotest and pre-commissioning, the liquids pipeline shall be left filled with treated water ready for commissioning.

4.3 12 inch tie-in from SP XI into the proposed SP XI Discharge Compressor and Pig Launcher

The proposed line from new gasline into the proposed SP XI Discharge Compressor will initially be used to supply gas from SP XI. It is intended that as part of gasline project will be split into two sections. The first section will run from new gasline to SP XI Discharge Compressor, and will supply gas from SP XI, replacing pipeline 12 inch existing for single line supply gas from SP XI to SKG II. The second section will run from gasline to Pig Launcher in SP XI, and will transport liquids from SP XI to SKG II for pipeline cleaning process.

The pipeline will be installed and tested by Contractor with a dummy flanged spool adjacent in SP XI Discharge Compressor and Pipeline in SP XI Pig Launcher. The spool will be removed as part of this Project to split the pipeline into two sections, and two points tie-ins will be installed. One to tie-in the gasline SP XI - SKG II into the SP XI Discharge Compressor section of the pipeline, and the other to tie-in the Pig Launcher section in SP XI.

The tie-ins shall be installed using the same line pipe. Pipeline wall thickness, coatings, and concrete weight coat will be the same as for existing pipeline. Spare 12 inch line pipe procured via this project by COMPANY shall be responsible for pre-formed bends (if needed), flanges and their fittings, and the associated coatings of the spools.

The tie-ins shall be routed to avoid possible conflicts with pipeline existing and pipeline of Pig Receiver. The routing must also allow space for the proposed future pipeline tie-ins from another gathering stations.

The SP XI - SKG II pipeline shall be isolated prior to the tie-in. A remote controlled mechanical isolation plug or similar equipment approved by COMPANY shall be set into position just past a removable spool.

GASLINE SP XI – SKG II PROJECT PT. PERTAMINA EP – FIELD LIMAU After hydrotest

GASLINE SP XI SKG II PROJECT PT. PERTAMINA EP FIELD LIMAU

After hydrotest and pre-commissioning, the liquids pipeline shall be left filled with treated water ready for commissioning.

4.4 Pipeline Tie-in

In the absence of specific information from the pipeline operator, the following assumptions have been made:

1. The pipeline operator from CONTRACTOR is responsible for the pipeline section from the downstream outlet flange.

2. The pipeline operator from CONTRACTOR will install the tie-in into the existing pipeline. The valves may be fitted either at the tie-in point or at the downstream flange.

3. The pipeline operator from CONTRACTOR will be responsible for all costs associated with providing the tie-in process.

4. COMPANY will operate the proposed pipeline system within the range 60 to 200 psi.

5. Both pipelines shall be rated to the same Maximum Allowable Operating Pressure (MAOP) of 1,000 psig. The pipeline operator from CONTRACTOR and COMPANY will ensure that the pipeline pressure protection devices on both pipelines are set so that the pipeline pressure cannot exceed 110% of the MAOP (ie 1100 psig).

5.0 DESIGN REQUIREMENTS

5.1 Material

The pipelines shall be constructed from API 5L Grade B, with a 3 mm corrosion allowance in accordance with Project Specification 003/2014-LMU-001.

5.2 Wall thickness

Wall thickness shall be designed to meet minimum requirements of:

(a)

Hoop stress (in accordance with ASME 31.8),

(b)

External buckling collapse (in accordance with ASME 31.8), and

(c)

Propagation buckling (in accordance with ASME 31.8)

The nominal wall thickness shall be determined in accordance with API 5L specified wall thickness.

The pipelines shall be constructed with a minimum wall thickness of 0.5 inches.

The tradeoff between the wall thickness and concrete coating thickness shall be considered in design optimization.

5.3 On-Bottom Stability

The pipelines shall be analyzed to ensure that they are stable on the above of ground. The concrete coating thickness and density shall be determined from this analysis.

The pipelines with minimum contents density shall be designed to withstand to 20 years current conditions during operation.

For installation, empty pipelines shall be designed to withstand of 1 year current conditions.

5.4 Vertical stability

Buried pipelines shall be subject to a vertical stability analysis during detailed design.

GASLINE SP XI – SKG II PROJECT PT. PERTAMINA EP – FIELD LIMAU Onshore pipelines

GASLINE SP XI SKG II PROJECT PT. PERTAMINA EP FIELD LIMAU

Onshore pipelines crossing swamp and paddy field area should be designed with appropriate weight coat, ground anchors, geotextile mat, engineered backfill and / or other means to prevent vertical movement.

5.5

Landfall Requirements

The pipeline must be buried to a depth of 2m to top of pipe up to the ground, or according to government regulations.

5.6

Expansion

 

Expansion analysis of the onshore pipeline shall be performed in accordance with ASME B31.8. Expansion loops shall be designed based on the expansion stresses determined from the expansion analysis.

5.7

Free Spanning

For all temporary and permanent free spans subjected to combined wind and current loading,

a

free span assessment shall be performed addressing the integrity with respect to buckling

and fatigue failure within the design life of the pipelines and supports. Short term fatigue following installation and prior to freespan correction shall be considered. Fatigue during installation in the event of an interruption to pipelay shall also be considered from the first tensioner to a point beyond the touchdown point.

5.8

Coatings

 

The pipelines will be coated with asphalt enamel for corrosion protection in accordance with Project Specification 005/2014-LMU-001.

5.9

Cathodic Protection

Zinc or other ground bed anodes shall be designed for the onshore pipeline section on the land section in accordance with Project Specification 006/2014-LMU-001.

5.10

Bends

 

A

minimum of 5D radius bends shall be used for pipeline tie-ins, onshore crossings.

5.11

Routing

 

The pipeline routing shall be planned with all tangent points, radius of curvatures, and lengths shown on the detailed design Drawings.

5.12

Crossings

 

All pipe crossings shall be identified and designed in accordance with ASME 31.8. Minimum separation taking into consideration short and long term pipeline and support settlements.

Road crossings shall be designed in accordance with API RP 1102, with the separation between the pipe and lowest point inside the road’s right of way clearly marked on the Drawings.

5.13

Constructability

Designed pipelines and supports shall be subject to constructability analysis with respect to combined external pressure, axial tension, and bending moment developing in the pipelines and supports during construction and installation.

Constructability shall be analyzed in accordance with ASME B31.8.

GASLINE SP XI – SKG II PROJECT PT. PERTAMINA EP – FIELD LIMAU 6.0 DESIGN

GASLINE SP XI SKG II PROJECT PT. PERTAMINA EP FIELD LIMAU

6.0 DESIGN DATA

6.1 Design Life

The design life for the pipeline is 20 years.

6.2 Pipeline design pressure

Table 6.1 Pipeline Design Pressure

Parameter

Unit

12 inch

Gas

Design Pressure

psi

200

Hydrotest Pressure

psi

376

6.3 Pipeline mechanical design temperature

Table 6.2 Pipeline Mechanical Design Temperature

6.4

Parameter

Unit

 

12 inch

 

Gas

Mechanical Design Temperature (at support inlet)

0

F

140

Hydrotest Temperature

0

F

80

Contents density

Table 6.3

 

Contents Density

Parameter

Unit

 

8 inch

 

Gas

Maximum Contents Density

lb/ft 3

 

5

6.5 Hydrodynamic coefficient

6.5.1 Hydrodynamic Coefficients for Pipeline Stability Design

Current Dominated Conditions (M>1)

Drag Coefficient

C D = 0.9

Lift Coefficient

C L = 0.9

Inertia Coefficient

C I = 3.29

Wind and Current Conditions (M<1)

Drag Coefficient

C D = 1.2

GASLINE SP XI – SKG II PROJECT PT. PERTAMINA EP – FIELD LIMAU  Lift

GASLINE SP XI SKG II PROJECT PT. PERTAMINA EP FIELD LIMAU

Lift Coefficient

C L = 1.5

Inertia Coefficient

C I = 3.29

6.5.2 Hydrodynamic Coefficients for Pipeline Spanning Design and Support Clamp Spacing Design

The following numbers are hydrodynamics coefficients used for spanning design:

Drag Coefficient

C D = 1.2

Inertia Coefficient

C I = 3.29

6.6 Material Properties

6.6.1 Pipeline / Support Material Properties

The line pipe material properties are for the Gasline SP XI - SKG II Project is presented in table below:

Table 6.5 Pipeline / Support Material Properties

 

Parameter

Units

Value

Grade

 

API 5L grade B

SMYS

psi

35,000

SMTS

psi

60,000

Young Modulus, E

psi

30 x 10 6

Poisson’s Ratio

 

0.3

Density

lb/ft 3

490

Coefficient of Thermal Expansion

/

0 F

6.5 x 10 6

Steel Potential

volt

-0.85

6.6.2 Pipeline / Support Coating Properties

 
 

Table 6.6 Pipeline / Support Coating Properties

Parameter

Units

Value

Support

 

-

Neoprene

Onshore Pipeline

 

-

Asphalt

Asphalt density

lb/ft 3

81

GASLINE SP XI – SKG II PROJECT PT. PERTAMINA EP – FIELD LIMAU

GASLINE SP XI SKG II PROJECT PT. PERTAMINA EP FIELD LIMAU

7.0

DOCUMENTATION

7.1 Design Report

A complete design report shall be prepared which includes the following as a minimum, plus any other documentation required:

(1) Detail description of the analysis procedures

(2) Wall thickness calculations

(3) Calculations for on-bottom stability analysis

(4) Pipeline expansion analysis

(5) Crossing span analysis

(6) Constructability analysis

(7) Upheaval and lateral buckling

(8) Impact and dropped object analysis

7.2 Report Requirements

7.2.1 Explanation of calculations procedures, assumptions, and sources of data shall be provided.

7.2.2 Pages shall be sequentially numbered within each section subdivision. A complete table of contents shall be provided and included with each volume. Individual volumes shall be clearly identified with titles and labels.

7.2.3 All calculations shall have the following:

(a)

Printed name (not initials) and signature of person making the calculation

(b)

Date

(c)

Page number

(d)

Project identification

(e)

Subject identification.

GASLINE SP XI – SKG II PROJECT PT. PERTAMINA EP – FIELD LIMAU 7.2.4 The

GASLINE SP XI SKG II PROJECT PT. PERTAMINA EP FIELD LIMAU

7.2.4 The calculations shall be made in U.S. Customary Units (i.e. foot, inch, and pound).

7.2.5 The calculations shall be archived by CONTRACTOR for the life of the facility, and shall not be destroyed without prior written COMPANY approval.

7.3 Drawings

7.3.1 Drawing title blocks shall be agreed upon prior to start of drafting.

7.3.2 Drawings shall be to scale and in U.S. Customary Units with the exception of Survey and positioning which shall be scale in SI units. Material and section callouts shall be in accordance with American Institute of Steel Construction (AISC).

7.3.3 Drawings shall be to the detail as defined by COMPANY.

7.3.4 A summary of the design criteria shall be shown on a general information and index drawing.

7.3.5 During construction, as-built revisions shall be kept on a set of Construction Drawing prints. At the completion of construction, the original drawings shall be revised to "As-Built Drawings" and reissued to COMPANY.

7.3.6 Drawings shall be numbered in accordance with Field Limau Drawing Numbering System.

7.4 Submission of Documents

7.4.1 Five copies of the design criteria shall be submitted for COMPANY approval prior to beginning the design.

7.4.2 Three copies of the Construction Drawings shall be submitted for COMPANY approval. COMPANY will return the Drawings within two weeks, either approved or with exceptions noted. Drawings shall be approved by COMPANY prior to beginning fabrication. COMPANY approval will be only for concept and contract compliance. Such approval shall in no way relieve CONTRACTOR of his responsibility per the Contract.

7.4.3 The documents shall be submitted in both electric and hard copy format at the end of project.

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