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Technical Assurance Services

T&D Design Authority

Germanischer Lloyd – Service/Product Description


Germanischer Lloyd – Service/Product Description

T&D Design Authority Contents

Service Title: Technical Assurance Services Page 3 Service Description and Values Generated

Lead Practice: GL Technical Assurance (Germany) Pages 4 - 8 Detailed Method Statement

The detailed method statements explain how the


work is conducted, which inputs are required and
which outputs and results can be expected.

a: Design Consultancy Service

b: Competent Design Authority

Pages 9 - 11 Case Studies and Examples

a: Design Authority Report on Overhead Lines &


Substation Close to High Pressure Gas Pipeline

b: Replacement Water Heating System at City Gate


Above Ground Installation (AGI)
c:
Optimisation of High Pressure Venting on HP Gas
Sites

2
SERVICE DESCRIPTION

Service Description
and Values Generated:
The increased demand for gas services worldwide also increases
demand for design expertise and know how. When gas is brought to
market via cross-country high pressure pipelines it is important to
ensure that the pipelines, associated plant and storage equipment are
designed to the highest National and International Standards.

a. Germanischer Lloyd (GL) offers a consultancy service that


provides solutions to the mechanical, electrical,
instrumentation, software and civil design-related issues
involved in the construction of high pressure pipelines,
storage equipment and pressure reduction plant. This
service is used by clients to support Feasibility, Conceptual
and Front End Engineering Design (FEED) studies.

b. GL acts as Competent Design Authority for the UK’s major


gas transporter, providing detailed design assessment and
appraisal of engineers engaged both internally and
externally by the company.

3
DETAILED METHOD STATEMENT

a. Design Consultancy Service Pipeline Feasibility

How: GL produce feasibility, conceptual and FEED studies GL evaluate the technical and economic issues that determine the
to support commercial and technical pipeline project connection of new gas supplies to existing or new gas networks. The
delivery. Perform gas network analysis and develop aim of a feasibility study is to determine the likelihood that gas
routing and costing options. supplies can be made available. This will involve an estimate of land
requirements, the impact of the pipeline construction on the
Input: User project scope requirements. environment demonstrated by a Preliminary Environmental Impact
assessment and identification of any relevant geographical and
Output: Optimum design solution for pipeline projects. archaeological features that would be met in the pipeline construction
phase.

Typically, a preliminary analysis of gas demand is undertaken and this


feeds into a Pipeline Investment Appraisal to examine demand growth
profiles with key inputs of:

 Capital costs

 Operating costs of the pipeline

 Annual and peak day transportation tariffs

 Annual demand volumes and growth during the pipeline


life cycle

GL have undertaken a large number of Feasibility studies for clients


both in the UK and worldwide. Customers include National Grid (UK),
Premier Gas (NI) and DEPA (Greece).

GL are involved in shaping legislation and standards that impact on


pipeline codes and standards, including the areas of pipeline design,
construction and operations. Important new legislation can be shaped
by GL’s input and advice, as we are recognised in the UK as being
among the leading experts in the field. An example is where GL
provided valuable expertise in assessing the impact of the European
ATEX regulations in the UK.

4
DETAILED METHOD STATEMENT

Develop Conceptual Study Front End Engineering Design (FEED)

The following elements are just some of the considerations in The FEED study will result in detailed engineering designs and the
producing a conceptual report on a pipeline project: determination of a fixed price for project investment and will form
the basis of for the award of a turnkey contract for Engineering
 Pipeline Design Premise - the design code of practice Procurement and Construction (EPC).
together with relevant specifications will be chosen at this
stage. The full range of design services is supplied by GL. We currently
employ Engineers in all pipeline disciplines and provide expertise in
 Pipeline Route Selection - The study should develop any pipeline design and routing, design of associated above ground
route options identified in the Feasibility study. The routes installations such as pig-traps, pressure reduction stations and
should be the shortest and most economic, taking metering installations.
account of ground conditions and environmental impact.
The route will seek to avoid sensitive areas, areas of The full range of electrical services are provided including the design
special scientific interest, forestry and wetlands. At this of earthing systems for pipelines and installations, over-voltage
stage, pipe dumps and proposed above ground protection of equipment form AC faults, lighting and switching
installations are considered. transients. The design of the E&I systems are based on the gas
industry standards/codes of practice.
 Pipeline Construction Considerations - The report will
include all major road, river and rail pipeline crossings. GL’s Electrical and Instrumentation engineers define, develop and
document the processes in designing safety-related instrument
 Pipeline Construction Budget and Schedule - A budget systems to reduce the risk of a hazardous event and eliminate the risks
cost estimate is done. The estimate will have an accuracy by defining the safety functions to be provided.
of typically +/_ 10% and will lay down construction and
commissioning timescales for the project. GL’s civil engineers provide design services that draw on their expertise
in structural steelwork, concrete, pipeline protection slabs, roads and
 Planning, Legislation and Consultation - Legal drainage. They can be called upon to provide expert advice on
considerations, such as the UK Gas Act, European specifications and standards for the design, testing and construction
Environmental and Planning legislation plus Health and of civil and structural works on high pressure pipelines and
Safety Legislation are identified and considered at this installations.
stage.
Equipment design and selection of items that include gas heaters,
regulators, valves, pipes, tees and fittings are undertaken by
GL’s experts in Pressure Control and storage. This includes the
knowledge of LNG and LP gas holder storage equipment. Our PCS
(Pressure Control and Storage) engineers are also engaged in
formulating standards by active involvement on IGEM (Institute of
Gas Engineers & Managers) committees plus CEN committees.

5
DETAILED METHOD STATEMENT

Pipeline Lifecycle

The diagram below shows a typical pipeline lifecycle and also the
areas where the Transmission and Control design team provide
expertise and input, namely the DESIGN BASIS DOCUMENT and
QUALITY PLAN, the SAFETY and ENVIRONMENT DESIGN and the
PRESSURISED SYSTEM DESIGN.

6
DETAILED METHOD STATEMENT

b. Competent Design Authority Process

How: By the use of a formal Modification Control GL uses a formal design appraisal process.
Procedure to control every phase of work from
design, to commissioning and record retention. This The design appraisal process applies to ALL works on pipeline pressure
will ensure compliance with industry standards and systems and is applied to all disciplines. It applies to ALL Instrument,
legislation, in particular, the Pressure Systems Safety Electrical and Software systems, not just those attached to pressure
Regulations 2000, Pipeline Safety Regulations 1996, systems. The role of the Competent Design Authority (CDA) is
Electricity at Work Regulations 1989 and the undertaken by GL Engineers when applied to NG designs and
Construction and Design (Management) Regulations modifications. GL, as an organisation, has unrivalled experience in
1994. this area due to the fact that we have undertaken in the region of
hundreds of design reviews, design audits, design appraisals and
Input: Customer design submissions assessments over the full range of disciplines such as Mechanical, Civil,
Electrical, Instrumentation, Software, Process, CP and Safety. We are
Output: New works and modifications carried out to existing the appointed Competent Design Authority in ALL these disciplines.
plant / equipment located on operational gas sites We believe no other organisation has the depth and breadth of
are conducted in an appropriate manner to meet expertise in this field as we have written, applied and amended the
industry standards and legislation requirements. process and have briefed the process out to National Grid (NG) and
it’s design organisations including Mouchel Parkman GEL, AMEC,
SERCK (approximately 12 design organisations in total).

The benefits of having GL perform this role as a single organisation,


are:-

1. Customer Service. Our design appraisers have ready


access to all of GL’s highly qualified and experienced
engineers.

2. Compliance. It is a fundamental element of the design


appraisal process that compliance to National and
International codes and specs are implemented. A major
benefit from using GL as the CDA is that our engineers
and staff write and update many specifications in their
daily work as well as undertaking assessments and
appraisals.

3. Control of the Business. The design process, if badly


managed, can cost a company both financially and by
harming their reputation. GL have long experience of gas
industry design.

7
DETAILED METHOD STATEMENT

GL work in accordance with the following UK industry documents: Systems

 IGE/GL/5 Plant Modification Procedures. The systems to control design appraisal process are a primarily a
number of specially developed databases and a national register. For
 T/PR/G/19 Management Procedure for NG Gas’ instance, GL manages and administers an Appraiser/Approver register,
Application of Model Design Appraisals. to formally register Approvers and Appraisers previously assessed as
being competent to do design appraisals and approvals.

The way GL controls the management of the CDA role is as follows: The number and types of design appraisal are held on a Pressure
Systems database which can track that status of a design appraisal at
 By the implementation of the Management Procedure for any given point in the process, as each design appraisal has a unique
Control of Modifications T/PR/G17. pressure systems identifier.

 By the establishment of the Competent Design Authority


for all disciplines.

 By the assessment and interview process for the


appointment of Approvers and Appraisers.

 By the registration and control of Approvers and


Appraisers, including establishment and maintenance of
the national register.

 By the implementation of a Deviation Procedure for


unavoidable non-compliances with National standards.

 By the implementation of an Audit process to ensure


compliance with requirements and make
recommendations for the improvement of the design
appraisal process.

GL developed an original design appraisal process, in partnership with


the UK’s major gas transporter, NG, and currently controls the
assessment and appointment of Appraisers and Approvers of all
disciplines. The design appraisal process has recently been expanded
by GL to include LNG plant as well as pipelines, AGIs and storage.

GL work to enhance and improve the design appraisal process by


expanding the assessment and appointment process to include, for
example, commissioning engineers. This would be part of a staged
process to make sure that all engineers involved in a role of design
appraisal will have been formally assessed as to their competence in
the role.

GL undertake training and assessment seminars specifically aimed at


design engineers to develop companies’ in-house capability to
undertake a greater amount of design appraisal in-house. This will
have a positive impact on costs and project timescales by eliminating
some of the requirement to externally source design expertise and at
the same time increase the engineering competence of staff. This
benefits a company’s business performance by adopting best practice
to manage value for money.

8
CASE STUDIES

a. Design Authority Report on Overhead Lines & Substation


Close to a High Pressure Gas Pipeline

Date: 2007
Customer: National Grid
Savings: Risk mitigation

Issue: Recommendation
Consideration should be given to measuring any standing voltages
AGI built too close to high voltage power lines. and current densities on the pipeline.

Resolution: Sub - Issue 3


Insulation Joints are typically installed on a pipeline as it leaves the
Examine implications on Cathodic Protection system AGI’s/PRS’s prior to the pipe-work heading belowground. Typically
insulating joints on a 69 BAR pipeline are tested at the manufacturers
in dry conditions to 3kV where they do not breakdown and pass
Method: current. However when damp and in a working environment the
insulation joints are considered to be good for 2kV.
Site survey and report on findings
GL considered given to two possible scenarios for the failure of the In-
sulation Joints:
Forsbrook 132kV Substation:
Earth Fault - Earthing Risk Management’s document ERM R202 covers
HV Overhead lines & Primary Substation close to HP pipeline risk to CP operators from an earth fault on the 132kV system at the
substation (the risk being within the broadly acceptable region – of 1
in 1.2m). The report also demonstrates that the voltage levels along
Sub - Issue 1 the gas pipeline fall off over distance and by the time they are at the
NG Procedure ECP/2 states that overhead lines (132kV or greater) insulation joints at both ends of the gas pipeline (i.e. AGI’s/PRIs) they
running in parallel with a gas pipeline should be avoided or at least have fallen away to under 185 volts.
minimised. The procedure gives separation distances for the overhead
line and pipeline and the distance that parallelism applies.
Recommendation
The length of the overhead line and pipelines parallelism was This level of voltage is well below the breakdown value of the
measured on a scaled drawing and found to be in the region of insulating joint so therefore no voltage from a Substation fault should
4.9km, with a distance between the overhead line and gas pipeline find its way onto the AGI.
measured as 75.2m.

Procedure also ECP/2 indicates that for parallelisms greater than 3km, Sub - Issue 4
the separation distance between the overhead line and the Lightning strike – A lightning strike on the 132kV or 33kv overhead
underground gas pipeline should be 500m. Distances closer than that lines. A lightning strike on these lines could travel and earth itself at
recommended in ECP/2 could give rise to both current density and the primary substation. The magnitude of the voltage and hence
voltages on the pipeline. current from the lightning strike could be higher than that from a
fault as mentioned above, with the potential to produce a voltage
large enough to breakdown the insulation joint with the subsequent
Recommendation potential explosion risk and instrument damage at the AGI.
NG should ensure that Procedure ECP/2 is made available and
understood by all parties contracted to work on Substations and Recommendation
overhead lines in the proximity of pipelines. NG should take steps to mitigate the risk of lighting strikes.

Sub - Issue 2
Overhead power lines can generate values of current density greater
than 100 A/m² on pipelines with the subsequent risk from AC corrosion.
At values of current density 30 A/m² the corrosion risk is uncertain.

9
CASE STUDIES

b. Replacement Water Heating System at City Gate AGI

Date: 2006
Customer: National Grid
Savings: Improvement in safety and efficiency

Issue:

Existing heating system is old and 50% efficient

Resolution:

Increase thermal efficiency of the system:

Method:

Provide a ‘Fit for Purpose’ design, inclusive of appropriate calculations, etc

To include:

 Design for the installation of the new heat exchangers,


to replace the existing water bath heaters.  Full Civil and Mechanical design appraisal of works.

 Design for the installation of the boilerhouse unit.  Provide Technical Support to Clients’ Site Personnel and
Construction Contractor.
 Design for the installation of the boiler gas breakdown
system.  Produce ‘as-laid’ package after installation complete,
installation and commissioning by others.
 Design the water and gas pipework between the
boilerhouse, heat exchangers and boiler gas breakdown  Produce on behalf of the client an initial Pre-Tender HS&E
feed system. Plan.

 Assess existing support slabs.  Produce a compliant stress analysis report on the new site
to IGE/TD/12.
 Design new slabs, supports and support bases as
required, installation and construction by others.  Produce hazardous area classification for complete site to
IGE/SR/25.
 Design new raft type foundation for boiler house unit,
installation and construction by others.

10
CASE STUDIES

c. Optimisation of High Pressure Venting on HP Gas Sites

Date: 2006
Customer: National Grid
Savings: Noise reduction and efficiency improvements

Issue:

High levels of noise associated with operational venting of high


pressure gas from gas compressor stations.

Resolution:

Examine existing practice for venting gas for routine and maintenance
operations.

Method:

Complete a design review of high pressure venting to include


establishing a record of HP venting operations in the UK.

Conduct an investigation of engineering and procedural requirements


and practices benchmarking against standards and practices.

Develop methodologies for predicting and reducing noise from


venting, testing of silencers and/or development and testing of gas
capture devices for emissions reduction.

11
Germanischer Lloyd
Industrial Services GmbH

Oil and Gas


Steinhöft 9
20459 Hamburg, Germany
Phone +49 40 36149-7700
Fax +49 40 36149-1781
glis@gl-group.com
Technical Assurance Services

 T&D Design Authority www.gl-group.com/glis

Germanischer Lloyd does not warrant or assume any kind of liability for the
up-to-date nature, accuracy, completeness or quality of the information provided.
Liability claims against Germanischer Lloyd arising out of or in connection with
material or non-material loss or damage caused by the use or non-use of information
provided, including the use of incorrect or incomplete information, are excluded
unless such loss or damage is caused by the proven wilful misconduct or grossly
negligent conduct of Germanischer Lloyd.
All offers are subject to alteration and are non-binding. Germanischer Lloyd expressly
reserves the right without notice to change, supplement or delete parts of the pages
or the entire offer or to stop the publication temporarily or definitively.

Issue no.001 15.05.2008