CRUDE TRANSPORTATION

CRUDE OIL IN SHIPS

FLOATING HOSES SPM SYSTEM UNDER BUOY HOSES PUMPING UNITS PIPELINE END MANIFOLD CROSS COUNTRY PIPELINE OFFSHORE LINE OIL FIELDS GATHERING STATION

SHORE TANKAGES

OFFSHORE / ONSHORE PIPELINE

REFINERY TANKAGE

PRODUCT TRANSPORTATION
REFINED PRODUCT FROM REFINERIES REFINERYs PRODUCT TANKAGE IMPORTED / OTHER PRODUCT IN SHIP/OIL JETTY TANKAGES

PUMPING STATION

PUMPING CUM DELIVERY STATIONS OR DELIVERY STATION

DELIVERY TERMINAL

INTRODUCTION OF PIPELINES IN OIL TRANSPORTATION

THE FIRST CROSS COUNTRY OIL PIPELINE WAS LAID IN PENSYLVANIA IN 1879 FROM BRADFORD TO ALLEN TOWN, ABOUT 109 MILES LONG AND 6 IN DIAMETER. THE LONG DISTANCE PIPELINE TRANSPORTATION GOT A BOOST DURING WORLD WAR II WHEN COASTAL TANKER TRAFFIC WAS DISRUPTED.

DISCOVERIES OF GIANT OIL FIELDS IN REMOTE PARTS OF THE WORLD LED TO PLANNING AND EXECUTION OF CORRESPONDINGLY LARGE PIPELINE NETWORKS.
THUS, PIPELINE INDUSTRY HAS GROWN IN PARALLEL WITH THE DEVELOPMENT OF WORLD OIL INDUSTRY OVER THE LAST ONE CENTURY.

DEVELOPMENT OF PIPELINES IN INDIA

MOST OF THE EARLIER REFINERIES IN INDIA WERE INSTALLED AT COASTAL LOCATIONS, THUS DEPENDING ON COASTAL MOVEMENT OF CRUDE OIL. FURTHER, THE REFINING CAPACITIES BEING LOW, THE PRODUCTS WERE EITHER CONSUMED LOCALLY OR TRANSPORTED TO THE CONSUMPTION CENTRES BY RAIL OR ROAD. AFTER 1960, MOST OF THE REFINERIES WERE INSTALLED IN LAND-LOCKED LOCATIONS AND CRUDE AND PRODUCT PIPELINES WERE PROMPTLY LAID. THE FIRST CRUDE OIL PIPELINE WAS LAID FROM DIGBOI OIL FIELDS TO DIGBOI REFINERY. DURING 1960-63, OIL INDIA LIMITED LAID THE FIRST TRUNK CRUDE OIL PIPELINE, 1156 KM LONG FROM NAHARKATIYA AND MORAN OIL FIELDS TO THE REFINERIES AT GUWAHATI AND BARAUNI. CONTD.

DEVELOPMENT OF PIPELINES IN INDIA

CONTD.

THE FIRST CROSS COUNTRY PRODUCT PIPELINE WAS LAID DURING 1962-64 TO TRANSPORT PRODUCTS FROM GUWAHATI REFINERY TO SILIGURI. SUBSEQUENTLY, A NUMBER OF PRODUCT AND CRUDE OIL PIPELINES WERE LAID IN THE 60S, 70S AND 80S, INCLUDING SUBSEA CRUDE OIL PIPELINES. THE PIPELINES LAID DURING THE 60S WERE DESIGNED, ENGINEERED AND CONSTRUCTED BY FOREIGN COMPANIES. HOWEVER, THE EXPOSURE TO THIS TECHNOLOGY ENABLED INDIAN ENGINEERS TO GAIN CONFIDENCE, AND THE PIPELINES WHICH CAME UP LATER, WERE DESIGNED AND CONSTRUCTED WITH INDIGENOUS EXPERTISE. THE COUNTRY TODAY HAS ABOUT 15,000 KM OF MAJOR CRUDE OIL AND PRODUCT PIPELINES.

Pipeline Project Conceptualisation

CROSS-COUNTRY MOVEMENT OF OIL

OIL
Vital Source of Energy Essential for Domestic, Industry, Agriculture & Transport Sectors

CRUDE OIL
FROM WELLS TO GATHERING STATIONS FROM GATHERING STATIONS TO REFINERIES FROM PORTS TO REFINERIES (IMPORTED/INDIGENOUS)

FINISHED PRODUCTS
FROM REFINERIES TO CONSUMPTION CENTRES FROM PORTS TO CONSUMPTION CENTRES (IMPORTED/INDIGENOUS)

TYPES OF PIPELINE PROPOSALS

New grass root pipeline proposals

Crude oil pipelines Product pipelines

Branch and feeder pipelines Augmentation of existing pipelines

Extension
New intermediate pump stations Loop lines (only for crude pipeline)

Combination of stations and loop lines

Entire line replacement

PIPELINE PROJECT CONCEPTUALIZATION CRUDE OIL PIPELINES

Based on grass root refinery/augmentation plan.

PRODUCT PIPELINES Based on supply / demand analysis by Planning Department.

Transportation model, based Programming is used for projections of a pipeline.

on Linear throughput

Pipeline System Design

PIPELINE SYSTEM DESIGN

Flow Through Pipelines
SDH/MAOP
Q

DISTANCE 0 L ELEVATION H H RESIDUAL HEAD h ENERGY EQUATION : For Flow as Q cu m/hr (MMTPA) STATION DISCHARGE HEAD (SDH) = F x L + (H- H) + h
where, F = FRICTION LOSS, MCL/ KM, : L = DISTANCE, KM H-H = ELEVATION DIFFERNECE, m ; h = RESIDUAL HEAD, MCL Uniform, level ground profile assumed

PIPELINE SYSTEM DESIGN

Steps Involved

Determination of major parameters.

Selection of probable sizes based on

experience.
Hydraulics, for all sizes. Selection - Size with least Present Value. System Configuration,

Capital & Operating Costs, Present Value

PIPELINE SYSTEM DESIGN

Major Inputs/Parameters Volume of flow : Throughput projections for 10/15 years. Length (Distance). Elevations/Profile/Terrain. Residual Head. Fluid characteristics : Specific Gravity, Viscosity, Pour Point, Yield Stress.

PIPELINE SYSTEM DESIGN

Major Inputs/Parameters Type of Prime Movers Location of Stations : IPS/DS/TS Marketing Tankage Time Schedule

PIPELINE SYSTEM DESIGN

Determination of Parameters Throughput : Refining capacity / Demand. Demand : Consumption centres. Distance : Source to destination - Route survey (Rec., Satellite, GIS, Detailed). Elevations, Profile, maps/surveys. Terrain : From

RH : As per requirement.

PIPELINE SYSTEM DESIGN

Determination of Parameters Friction Loss : By calculation, based on fluid characteristics. Type of Prime Movers : Based on availability of reliable power/economics. Location of Stations : As per hydraulics, delivery requirements, civic amenities. Marketing Tankage : Based on Interfaces/ Minimum Batch Lengths/ Marketing norms.

PIPELINE SYSTEM DESIGN

Pressure Loss in Pipelines
PRODUCT PIPELINES P = 6.38 * 108 * Q2 * f * s / D5

f (friction factor) is calculated by Colebrooke Formula

1/f (1/2) = 1.14 + 2 log10D/E - 2 log10[1+9.28/(Re x (E/D) x f (1/2))]
where,

P Q E s D Re

: pressure loss in kg/sq cm/km : flow rate in cu m/hr : absolute roughness in mm : specific gravity : inside dia of pipe in mm : Reynolds number

PIPELINE SYSTEM DESIGN

Pressure Loss in Pipelines
REYNOLDS NUMBER

Reynolds number is calculated as under for use

in the friction factor correlation. Fundamental equation : Re = vD/Z where, v : fluid velocity (m/sec) D : inside pipe diameter (m) Z : kinematic viscosity (m2/sec)

PIPELINE SYSTEM DESIGN

Maximum Allowable Operating Pressure (MAOP)
MAOP =

S x 2T x S.F. D

where,

S T D S.F.

: yield strength (psi) : wall thickness (inches) : outer diameter of pipe (inches) : safety factor (0.72, 0.65)

Result in psi. Divide by 14.22 to get MAOP in kg per sq cm.

PIPELINE SYSTEM DESIGN

No. of Pump Stations
Calculate SDH required as per energy equation. If SDH required > MAOP, more than one stations necessary. Depending on value of SDH / MAOP, determine number of stations. Minor variations could be taken care of by providing higher wall thickness and/or higher grade pipe. Adjustment may be required depending on location.

PIPELINE SYSTEM DESIGN

No. of Pump Stations
Case I : SDH < or = MAOP Case II : SDH > MAOP & < 2 MAOP i.e. SDH/MAOP between 1 & 2 Case III : SDH > 2 MAOP & < 3 MAOP i.e. SDH/MAOP between 2 & 3
SDH

Q3 Case III

Q2 Case II

Q1 Case I

Q3>Q2>Q1

PIPELINE SYSTEM DESIGN

No. of Pump Stations - Adjustment for Peaks
Ground profile may not be uniform : peaks inbetween. Selected hydraulic gradient between end points may not cross the in-between peaks.

Minor variations could be corrected by using

higher SDH in the same system with higher wall thickness and/or higher grade pipes. Major variations may require addition of pump station.

PIPELINE SYSTEM DESIGN

Adjustment For Station Location
Necessary for selecting a better location. Could be done by:
Providing higher wall thickness/grade pipe Suitable for new pipelines. Example : Relocation of IPS to Bolpur in HBCPL by providing higher WT for 30 km. For existing/new (Crude oil) pipelines. Example : Relocation of IPS in V-K section at Bareja by providing 17 km loop line.

Providing loop lines

PIPELINE SYSTEM DESIGN

Horse Power Requirement
Q x H x s x 1000 B.H.P. = ----------------------------75 x n1 x n2
where,

Q : flow rate (cu m/sec) H : station discharge head (m) s : specific gravity n1 : pump efficiency n2 : transmission (Gear Box) efficiency Installed Horse Power = 1.1 x B.H.P.

PIPELINE SYSTEM DESIGN

Line Size Optimisation
Based on projected throughput, different line sizes are selected for detailed analysis.

Line size
Diameter Thickness Grade (API) - API 5L X (SMYS)

3 Diameters x 2 to 3 WT x 2 to 3 Grades:
12 to 27 options. Short-listing by elimination.

PIPELINE SYSTEM DESIGN

Line Size Optimisation For each size, the following are worked out:
Hydraulics & System Configuration

Capital Cost
Operating Cost Phasing of capital cost

Other costs like tankage

Present Value of costs for 35 years of operation

Pipeline size having least Present Value of costs is considered as the optimum size.

PIPELINE SYSTEM DESIGN

Components of Capital Cost
Survey and field engineering Land acquisition, ROW & crop compensation Office building and colony Project management and engineering, insurance Mainline pipes

Mainline materials
Mainline construction Pump station and terminal

Cathodic protection
Telecommunication & telesupervisory Interest during construction

PIPELINE SYSTEM DESIGN

Components of Operating Cost
Consumables
Fuel Lube Chemicals

Utilities (power & water) Labour Repair & Maintenance

Mainline Pump station etc.

General Administration expenses

PIPELINE SYSTEM DESIGN

Phasing of Capital Expenditure
For determining year-wise capital requirement, loan repayment schedule, interest etc. and for financial analysis Based on time schedule for the project. Capital cost & duration of each activity worked out. Year-wise expenditure for each activity calculated, based on its duration. Phasing of expenditure i.e. year-wise capital required during the period of execution of the project is calculated by adding the yearly expenditures required for different activities.

PIPELINE SYSTEM DESIGN

Line Size Optimisation - Example Alternative sizes
14,0.25 Capital cost Operating cost Total capex 35 years Total Capex + Opex PV of capex PV of opex 20,167 777 20,167 46,974 15,839 4,788 12,0.25 19,183 808 19,183 10,0.25 18,187 961 18,187

Total opex 35 years 26,807

27,876
47,059 15,066 4,979

33,155
51,342 14,284 5,921

Total PV
Rank

20,627
III

20,045
I

20,205
II

(Length of P/L : 240 km, Cost Figures in Rs. Lakh)

Augmentation of Pipelines

AUGMENTATION OF PIPELINES
Crude oil pipelines Loop lines Intermediate pump stations Combination Product pipelines Intermediate pump stations

AUGMENTATION OF PIPELINES
By Loop Lines
Q
Q/2 Q

Q/2

V=Q/A, i.e. V is directly proportional to Q F=fLv2/2gd, i.e. F (friction loss) is directly proportional to square of velocity. With loop lines, velocity reduces to half, so overall friction loss for the system reduces significantly. This enables higher flow rate at same SDH.

AUGMENTATION OF PIPELINES Reduction in Friction Loss with use of Loop Lines

Friction Loss (mcl/km) for Throughput (MMTPA)

Dia
12.75 18 24 28

1
1.1 0.203 0.05 0.023

2
3.82 0.69 0.17 0.08

3
7.97 1.44 0.348 0.16

4
13.49 2.43 0.58 0.27

5
20.32 3.64 0.87 0.41

6
28.47 5.07 1.21 0.57

Calculation of Loop Line Length : By Energy Equation

SDH = Fx(L-l)+ fxl + (H-H) + RH

FxL + (H-H) + RH - SDH OR, L/L length l = ------------------------------------(F-f)

AUGMENTATION OF PIPELINES
By Intermediate Pump Stations
SDH

Q3

Q2

Q1

Q3>Q2>Q1

Thank You