Process Design Basis Lpg Pipeline
PROCESS DESIGN BASIS LPG PIPELINE
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TABLE OF CONTENTS
1.0 INTRODUCTION...... 3
2.0 BASIC PARAMETERS...... 3
3.0 PROJECT SCOPEAND BATTERYLIMITS...... 4
4.0 PIPELINEPARAMETERS...... 5
5.0 DESPATCHSTATION PARAMETERS...... 7
6.0 RECEIPT STATIONPARAMETERS...... 7
7.0 INSTRUMENTATION...... 12
8.0 METERINGSYSTEM...... 12
9.0 SCADA& TELECOMMUNICATIONSYSTEM...... 13
10.0 LEAK DETECTION &OTHERAPPS SYSTEM:...... 13
12.0 GENERAL PROJECT SPECIFICATIONS...... 13
13.0 SPECIAL REQUIREMENTS...... 14
14.0 EXCLUSIONS...... 15
ANNEXURE-I SPECIFICATIONS /PROPERTIES/COMPOSITIONOFLPG
ANNEXURE-II LPGDEMAND RATES ATVARIOUS LOCATIONS DESIGN
THROUGHPUTS FOR VARIOUS PIPELINESECTIONS
ANNEXURE-III GROUND PROFILE
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1.0 INTRODUCTION
About the Project
2.0BASIC PARAMETERS
2.1 / Products to be transported / Liquefied Petroleum Gas (LPG)2.2 / Product properties/composition / As per ANNEXURE-I
2.3 / Pipeline Design Throughput, MMTPA / As per siterequirements/conditions
2.4 / Turn Down / Demand of RTfor 1st year or the minimum
continuous flow of Booster / Mainline pumps whichever is higher.
2.5 / Design codes / ASME B31.4, OISD 214 and OISD 141 will be followed as applicable. However, in case of contradictory stipulations, the more
stringent of the above code requirements
will prevail.
2.6 / Design capacity of pumps / Pumps shall be specified for maximum flow achievable considering MOP of pipeline.
2.7 / Sparing philosophy for pumps / 100% for Single pump (1W+1S)
2.8 / Type of pump driver / Electric Motor driven pumps with VFD for Mainline Pumps/DOL for Booster Pumps
3.0 PROJECTSCOPEANDBATTERY LIMITS
3.1 PROJECTSCOPE:
-PumpingstationcomprisingofBoosterPumps,MainlinePumps,Filters,Custody Transfer Meters, ControlValves, ScrapperTrapsatDispatchTerminal foronlinepumping.
-ReceiptterminalscomprisingofFilters,CustodyTransferMeters,ControlValves, ScrapperTraps.
- Telecom/SCADA System.
3.2 BATTERY LIMITS:
DispatchTerminal : InletflangeofMOVoninletheaderof
BasketFilters.
Receipt Terminal : Outletflange ofROV ofMeteringskid.
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4.0 PIPELINE PARAMETERS
4.1 / Pipeline operating life / 25 years4.2 / Operating Hours / 8000 Hrs/Annum
4.3 / Pipeline Length / KM / (approx)of”NB.
4.4 / Basisfor hydraulicCalculation / HydrauliccalculationswillbebasedonLPGsupplytemperature
(i)As per the site condition of Despatch
(ii)Terminal
(iii)LPGspecificationsfromDespatchTerminalshallbeconsideredfor Hydraulics.
4.5 / Main Pipeline Diameter
4.6 / Pipeline roughness / 45 microns
4.7 / Material ofConstruction for
Pipeline / CarbonSteelas per Pipe size.
4.8 / Pipeline Corrosion Allowance / 0.5mm
4.9 / Pigging Facilities / Permanent Pigging facilities suitable for“IntelligentPigging” shall beprovided. IntermediatePiggingstationswillbeprovided atsuitable locationsbetweenKochiRefinery DispatchTerminalandSalem.
4.10 / Subsoil temperature
(1mbelowground) / 25oC throughout the entire length of thepipeline.
4.11 / MaximumOperatingPressure(MOP) / 10%belowDesign Pressure.
4.12 / Maximum Allowable
Operating Pressure(MAOP) / Design pressure
4.13 / Design Pressure / ---kg/cm2g (as per selected pipe)
4.14 / Designtemperature / Buried : 45oC/ (-)27oC
Above ground : 65oC/(-)27oC
4.15 / Surgecontrol / The surge analysis will be done during theprogress ofdetailed engineeringconsidering ROVclosure timeof3 secondsatallReceipt Stations.Suitablesurge control/surgerelief systemwill be provided,if required.
4.16 / Pipeline laying / Buried
4.17 / Pipeline corrosion protection system / Pipeline shall be protected from external corrosion by 3LPE external coating, andimpressedcurrent cathodicprotection.
4.18 / Corrosion Monitoring System / Online Corrosion monitoring systemcomprisingofcorrosion sensingprobes and corrosioncouponsshall beprovidedatsuitable locations
4.19 / GroundProfile / Asper detailed route survey
4.20 / Sectionalizingvalves / SectionalizingValveswillbeprovidedasperASMEB31.4OISD 214,141andBS-105 (RDSO guidelines).Valvesshall be Electric Motoroperated.
4.21 / Designmargin(forpipeline) / Onflow : 25% (AsperPNGRB)
On length : 3%
4.22 / Powersupply / Power supplyto Stations/IPstationswillbedrawn fromthe grid power/ DG/TEG, wherever applicable. (Shall be coveredunder EngineeringDesign Basis.)
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5.0 DESPATCH STATION PARAMETERS
5.1 Dispatchterminal
5.1.1 / Location / To be mentioned5.1.2 / Source of LPG / Mounded Storage/Sphere
5.1.3 / Design conditionsofLPGBullets / Pressure :14.5kg/cm2g +statichead
Temperature: 55oC/(-)27oC
5.1.4 / Supplytemperature,ºC (min/max) / 20/38
5.1.5 / Supplypressure,kg/cm2g
(min./nor/max) / 2.9/9.9/14(Note-1)
5.1.6 / Elevation differencebetween storagebottomandbooster
pumps. / As per site measurements
5.1.7 / Pipingdistancebetweenthe
farthest storageand booster pumps. / As per site measurements
5.1.8 / Max.flare backpressureat safety valve inlet/at unit B/L, kg/cm2g / 1.7/1.5
Note-1: Themaximumoperatingpressurespecifiedcorrespondingtothedesignconditions forLPG storage bulletskeepingintoconsiderationstandard designmargins.
6.0 RECEIPTSTATION PARAMETERS
6.1.1 / Batterylimitpressure, kg/cm2g / 13 atReceipt terminal outlet battery limit (Note-2)6.1.2 / Distance of metering stationLPGstorage
bullets
6.1.3 / Setpressureofsafety
valves onLPG Mounded Bullets kg/cm2g
Note-2: Basedonbatterylimitpressure,pressureatinletofflow metershallbecheckedto ensure thatitisatleast equalto 1.25 timesvaporpressure at maximumarrival temperatureplustwicethe meterloss(Asper requirementof GPSASECTION-3 “Measurements”andAPIManualofpetroleummeasurementstandardsChapter14 para4.1).Accordinglybackpressurecontrol valve will be specified.
6.2 UtilityConditions at B/L
6.2.1 Despatch Terminal
Sl.No. / Parameters / PlantAir / Service Water / Nitrogen6.2.1.1 / Source
6.2.1.2 / DewPoint,oC / NofreeWater / (-)100oC
6.2.1.3 / Pressure, kg/cm2g
(min/nor/max/des) / 2.5/3.5/5.0/10.5 / 2.5/4.0/5.0/7.5 / 1.5/2.5/7.0/10.5
6.2.1.4 / Temperature,oC (min/nor/max/des) / -/Ambient/-/65 / 30/35/45/65 / -/Ambient/-/65
6.2.1.5 / Consumption / 170 Nm3/hr
(Intermittent for cleaning, drying
etc.) / 5 m3/hr
(intermittentfor flushing,
cleaningetc.) / 170 Nm3/hr
(Intermittent for purging and
inertization etc.)
6.2.1.6 / Quality / Oil Free
Power / Source:
Emergency Power
(lighting/controls) / DGsetTobeprovidedforcontrolroomfacilities,criticalvalves (allstationinletoutletMOVs,StationPumpby-pass
MOVs,Control valves), Instrumentation &Yardlights.
6.2.2 Receipt Terminal
Sl.No. / Parameters / PlantAir / InstrumentAir / Service Water6.2.2.1 / Source
6.2.2.2 / DewPoint,oC / Nofreewater / (-)40oC / --
6.2.2.3 / Pressure, kg/cm2g
(min/nor/max/des) / 2.5/3.5/5.0/10.5 / 2.5/4.0/5.0/7.5
6.2.2.4 / Temperature,oC (min/nor/max/des) / -/Ambient/-/65 / 30/35/45/65
6.2.2.5 / Consumption / 170 Nm3/hr
(Intermittent for cleaning, drying etc.) / 5Nm3/hr / 5 m3/hr
(intermittentfor flushing, cleaningetc.)
6.2.2.6 / Quality / Oil Free / Oil Free
Power / Source:
Emergency Power
(lighting/controls) / DGsetTobeprovidedforcontrolroomfacilities,criticalvalves (allstationinletoutletMOVs,StationPumpby- passMOVs,Controlvalves),InstrumentationYard lights.
7.0 INSTRUMENTATION
7.1 / General / Adequate instrumentation and control system will be providedforsafeandefficientoperation.PLCbasedcontrolsystemshall be provided atdispatchand receiptstations. SupervisoryControl andDataAcquisition (SCADA)system shall be designedfor Remotemonitoringandcontrol.7.2 / Type ofcontrol / Electronic
7.3 / Final control element / AtDispatchTerminals:Electro-Hydraulic
AtReceiptTerminals: Pneumatic
7.4 / Remote OperatedValve (ROV) / Pneumatic
7.5 / Safetyvalve isolation / Safetyvalveisolationwillbeprovidedwhereverrequired.Theseisolation valves shall be lockedopen.
7.6 / Block and bypassvalves for control valves / Asper design
8.0 METERINGSYSTEM
8.1 / Flowmeters / Coriolistypemassflowmeterswithonesparerunshallbe provided atdespatch and receipt terminalsfor custody transfer aswellasleakdetectionpurpose.The flow meterwithonesparerunwillbeprovidedatIP station forleakdetectionpurposedependinguponthe recommendation oftheleakdetection vendor.8.2 / Meterprover / CommonMeterProver(Bi-directional)shallbeprovidedatdespatch terminal.
8.3 / Unitsof custody
transfer / Tonnesper hour
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9.0 SCADATELECOMMUNICATION SYSTEM
SCADA and Telecommunication systems for the entire pipeline will be provided to ensure effective and reliable control, management and supervision of the pipeline from a centralized location using Remote Telemetry Units (RTU) along the pipeline route at suitable locations.
9.1SCADA monitoring: The SCADA master control station (SMCS) shall be located at Despatch Terminal. Remote work stations (RWS) shall be located at all Receipt Terminals.
10.0 LEAK DETECTION &OTHERAPPS SYSTEM:
Real time leakdetectionsystemintegratedwith SCADA networkwill be provided.
11.0 METEOROLOGICAL DATA
Location / Ambient temp.Deg C / Altitude ,Mabove MSLMin. / Max.
20 / 38
20 / 38
12.0 GENERAL PROJECTSPECIFICATIONS
12.1 Numberingsystem to befollowed:
12.1.1 / Unitnumbers / Pipeline / :DT / :
RT / :
12.1.2 / Equipments
12.1.3 / Instruments
12.1.4 / Drawings/Documents / Asper BPCL
12.2 UnitsofMeasurement: Metric,unless otherwise specified
13.0 SPECIALREQUIREMENTS
13.1 Runningindicationofdispatchterminalpumpsshouldbe available
atpipeline control room throughSCADA.
13.2 Atdispatchterminal,depressurizationlineaswellasallventlines shallbeconnected withtheflareline.Flareload for controlleddepressurizationofpipeline sectionshall becalculated.Mobile flareto beconsidered at allotherstationsforemergency evacuationofpipelineinventory.Mobileflares shallbeprovidedfor thispurpose. ColdFlaringshallbe consideredat alltheSVs, IPs, and RTs.
13.3 Thereisno requirementofCorrosioninhibitorchemicalinjectionas the LPGis free of water.
13.4 Onlineanalyzertomeasure freewaterinLPG,Sulfur/H2Sanalyzershallbeprovided atDispatch Terminals.UVdetectors forMVspraysystemare tobeprovided. Gas Chromatographisnot required.
13.5 CCTV cameras to be installed ateach ofthe areasviz.,boosterpumps,mainline pumps andmetering system,atDispatchTerminals,SVs, IPsand Receipt Terminals.
13.6 Tap-Off tobeprovidedif required.
13.7 Filters,Metersandcontrolvalvesatthedispatch terminalsshallbedesigned for the maximumflow specified forrespectivepumps.ForRT,theseshall bespecified for maximumthroughputachievableatthisterminalconsideringMOPof pipelineas90kg/cm2g.
14.0 EXCLUSIONS
Mention If any
ANNEXURE-I
SPECIFICATIONOFLPG ATDT(As perIS4576:1999)*Characteristics / Unit / Specification / TestMethod
Hydrogen Sulfide / Pass (Note-2) / D 2420
DoctorTest (Note-1) / Yellowish Brown / P:19
Total Volatile Sulphur, max / ppm / 150 / D 3246
Specific Gravity@ 15.56 °C / 0.545-0.571 / P :76
Composition (Butane-Propane mixture)# / Mol%
VapourPressure@ 40°C / kPa(g) / 520-1050 / D1267
Volatility,Evaporation temperaturefor95
vol%at760mm Hg, max / DegC / 2.0 / D1837
CopperStrip corrosiontest@38 °Cfor1
Hour / Notworst than 1 / D 1838
Free water / ppm / NIL / Visual
# Mixed composition ofLPG from various souces.
AUTOLPGSPECIFICATION(As perIS14861:2000) *Characteristics / Unit / Specification / TestMethod
C5Hydrocarbons andheavier,max / Mole% / Max.2.0 / D2163
Copperstripcorrosion@40°Cfor1hr / MAXClassI / ISO6251
Dienes(as1,3butadiene) / Mole% / Max0.5 / ISO7941
EvaporationResidue / Mg/kg / Max100 / ISO13757
Freewater content / Nil / ASTME700
Hydrogensulfide / Pass/Fail / ISO8819
MotorOctane Number / Min88 / ISO 7941(+ ANNEXE A)
Odour / Unpleasant& distinctivedown to20%LEL / ODOUR
Specific gravity @ 15.56°C / Report / P:76
Totalvolatile sulfur / Ppm / Max150 / D3246
Vapour Pressure @ 40 °C / Kpa(g) / 520-1050 / ISO4256
Note-1: Product shall contain minimum 20 ppm ethyl mercaptans at the first dispatching location to ensure the detection of odour. To detect the odour, the following procedures may be adopted:
5 ml Doctor Solution + 8 ml Iso-octane + Pinch of sulphur powder in 25 ml stoppered cylinder. Shake and add 2 ml LPG (Aq.) Shake slowly by releasing pressure. Odour isadequate if sulphur turns yellowish brown.
P: 75 Odour test method may also be acceptable as an alternate method.
Note-2 : „Pass‟ test indicates Hydrogen Sulfide not more than 5 PPM.
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