Bos2 Chain Units Pipelines

7/30/2019 Bos2 Chain Units Pipelines

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Master course on CCS,University of Zagreb

6-7 May, 20

Chain units: pipelines

Assessing CarbonCapture and Storage(CCS) value chains

May 6th, 2011


Slide 26-7 May 2011, CCS master course University of Zagreb

CO2 value chain


Ref: www.sintef.no/ecco


Transport

Pipe line Sh ip

Source

Industry PowerPlant

Storage / Sinks

Buffer Geology

Pipeline

1

Pipeline 4

Pipelin

e5

Pipeline

3

Define Network / Components / Contracts

PowerPlant w/

Capture

EOR Field

Pipeline

2

Steel Mill

w/ Capture

DGF1-n

The Network can build-out with time as components are added

ECCO tool: integrated technical/economical CCS evaluation tool

Contracts

C1-nTSO1-n SO1-n

Tool output:

Tech KPIs

DCF-KPIs

Planning charts

EUA price

Cost indices

Govt matchingfunds reqd

Initially LTcontracts?Later, moreST?


Pipelines(general)

6-7 May 2011, CCS master course University of Zagreb

Offshore gatheringsystem and ControlRoom in Den Helder


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Classification of pipelines

Fluid content (gas, oil, water, or mixturesof all three)

Offshore or onshore

Buried or on surface (both offshore oronshore)

Construction material

Type of corrosion protection

Insulated or non-insulated


Pipeline construction Saudi Aramco


Pipeline construction EuropeSlide 106-7 May 2011, CCS master course University of Zagreb

Alaskan pipeline


Pipeline

through theMexicanmountains


Procedure for sizing a pipeline

Four principal considerations:

1. maximum pressures the pipeline will have towithstand at any point along its length

2. maximum throughput

3. pressure drop that can be allowed

4. upside throughput potential needs to beallowed for


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Necessary to calculate the relationship betweengas throughput, inlet and outlet pressures and

pipeline diameter and length.

Not a simple matter, since the flow ismultiphase (liquid and gas) and the pipeline isnot horizontal.

Generally a multiphase flow computer simulatorwill be used.

Calculating the required pipeline size


Slugcatcher,

Den Helder NL


In simple situations, analytical correlations may beuseful. For example, for a level gas pipelinecontaining no liquids, the AGA equation can beused

pin2 - pout

2 = C L f z T q2/ d5

Reynolds number is usually high, for a gas we cannearly always use the Colebrook-White equation:

f = { 2 log10 [3.71d/]}-2

is the roughness of the pipe

Calculating the required pipeline size


Factors in pipeline design - 1

Type of material

Type and grade of steel

Linepipe manufacture

Weldability

Selection of the pipeline route

Burial

Stresses and loads


Pipelineburial

onshore


Factors in pipeline design - 2

Corrosion

Temperature control

Hydrate formation

Inspection

Cleaning

Valves and other components


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Insulatedpipeline


Weighted pipes to prevent buoyancy


Pipeline pigSlide 226-7 May 2011, CCS master course University of Zagreb

Pipelinepig


Pipeline laying methods

laybarge or layship

towing


Pipelinetowout

GullfaksSouth

Norway


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Layout of a pipe-laying vessel


Pipelineentering the

water from apipe-layingvessel


Methods of laying offshore pipelinesfrom ship or barge

S-lay

J-lay

Extended S-lay

Reeled method


Pipelayingoffshore

S-lay


AllSeas Lorelay pipe-laying vesselSlide 306-7 May 2011, CCS master course University of Zagreb

AllSeas Solitaire pipe-laying vessel

Length 300m = largest in the world. Dynamic Positioning using 10screws. Main advantage of Solitaire is preparatory welding work of 2 pipes @12m in

preparatory welding lanes. Only thereafter do the 24 m sections come onto the main welding lane: fa ster

welding (double speed). There are 9 welding stations in main lane. Speed is 24m each 5-7 min = 5-6 km /

day non-stop.


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Slide 316-7 May 2011, CCS master course University of Zagreb Slide 326-7 May 2011, CCS master course University of Zagreb

Solitaire: combating weld fatigue

Challenge

Fatigue Enhancement in the Cantilever of the StingerHandling System

Solution Treat existing and repaired welds with UIT

Post-weld fatigue improvement technique using UltrasonicImpact Treatment = optimising shape of weld

Fatigue tests preceding treatment

Benefits Reduction of Down Time

Enhanced Fatigue Life


Inside AllSeas SolitaireSlide 346-7 May 2011, CCS master course University of Zagreb

Welding device


Solitaire test-welding stationSlide 366-7 May 2011, CCS master course University of Zagreb

EPTM

LB 2000laybarge


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Saipem vessel with a 135m J-lay tower

Pipe stalks with a length upto 6 joints are upended andwelded to the seagoing pipe in a near vertical ramp.

Pipe leaves the lay system in an almost vertical position


J-lay pros and cons

Pipeline is only bent once during installation (at theseabed) advantageous for installing pipelines that are sensitive to fatigue.

Reduced stress on the pipe allows J-lay to work indeeper water depths.

Can withstand more motion and underwater currentsthan pipe being installed in the S-lay fashion.

Relatively low production rate due to the singlewelding station.

Less suitable for shallow waters as this requires asteep departure angle.


Extended

S-lay indeep water

max 1800 m


Allseas Solitairelaying 24'' pipelinein deep water for

Shells Malampaya

project in ThePhillipines

504 km of pipe

5-6 km/day


Pipelinelaying for

Gullveigsatellite inNorway(reeled method)


Pipeline trenching methods

ploughing

jetting

mechanical excavation

fluidisation

dredging


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Trenchingtechniques


Rock -dumping


Solitaire: own supply of rocks


These procedures give a first approximation fora screening study.

Capital cost, pipe diameter and required designpressure must be verified as soon as firm datais available on fluid properties and tie-inpressures

Value of simple costing methods


Offshore pipeline cost parameters

Direct costs Pipe diameter D in inches, weight in kgEngineering 0.4 million $ + 6$/m

Line pipe 1.3 $/kg

Corrosion coating 9D$/mWeight coating 7D $/m

Other material cost 1.2D $/mTie-in or riser cost (each) 0.26D million $Installation cost 0.6D million $ + 60D $/mTrenching and dumping cost 0.4D million $ + 16D $/m/passMiscellaneous Factor 1.1 to 1.3

S ho re appr oach/landfall 2 - 10 million $ ( ver y var iable )

Indirect costsManagement & supervision 5% of direct costs

Insurance 2% of direct and indirect cost

Pipeline costing rules of thumb

Note: obsolete figures!


Weight of line pipe for costing

Pipe Diameter Wall Thickness Weight

inch mm inch mm kg/m

12 324 0.312 7.9 61.7

14 356 0.375 9.5 81.5

16 406 0.406 10.3 100.718 457 0.469 11.9 130.8

20 508 0.500 12.7 155.1

22 559 0.562 14.3 191.6

24 610 0.625 15.9 232.4

26 660 0.688 17.5 277.0

28 711 0.750 19.0 325.1

30 762 0.750 19.0 349.0


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02468

101214161820222426

2830323436

0 2 4 6 8 10 12 14 16

Gas million cubic meter/day

THROUGHPUT

Pipediameter(inche

s)

Oil thousand bbl/day

10 20 30 40 50 60 70

GAS

OIL

Quick sizing procedure


Pipelines and CO2


CO2 transport & injection Complex due to phase changes

supercriticalLiquid

Gas

Solid

Pipeline

Reservoir (LD)

Reservoir (HD)

Injection(LD)


CO2 phase diagram

Critical point at 31.1C, 73 atm.

Supercritical state requires much less compression power for transport

But seabed water 4-10C.


Useful reference (2006)

Techno-Economic Models for Carbon DioxideCompression, Transport, and Storage &Correlations for Estimating Carbon Dioxide

Density and Viscosity

By David L. McCollum, Joan M. Ogden

Institute of Transportation Studies, University ofCalifornia


CO2 transport: Pump & compressor

power requirement (gas vs. supercritical)


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Pump & compressor capital costs


Pipeline capital cost vs. mass flow rate


Pipeline capital cost vs. length


Pipelines in ECCOtoolUserInputShee t

Pipeline Module 1 from Hamburg IGCCto Ekofisk EOR

Pipeline Type Pipeline Parameters Values Pipeline Name Routing points

Mild steel 100% U ni t s D ef au l t U se r G IS E as t G IS N or th

Stainl ess steel Design Max imum Pressure bar 190 9.97 53.87

D es ig n M ax im um Fl ow ra te M t/ a 5 Location points (Deg 2dp)

Terrain D es ig n M in S af e O ut pu t P re s su re b ar 8 0 Start module

Default User Ambient Temperature C 4 Hamburg IGCC

Onshore - Flat rural Leakage % 0% 10.00 53.50

Onshore - Urban Constructi on Employment FTE No. 2 End moduleOnshore - Hills Permanent Employment FTE No. 0 Ekofisk EOR

Onshore - Mountai ns 3.20 56.50

Onshore - average 5% Derived Values Units Value UserOffshore - Sandy seabed Pipeline length km 559

Offshore -Trenched Pipeline Diameter mm 457 610 Pressure Drop OK

Offshore - Diff icult Pipeline wall thickness mm 18 24 Hoop Stress OK

O ff sh or e - A ve ra ge 9 5% D es ig n P re ss ur e D ro p( Ma x) b ar 1 0. 6

TOTAL 100% 0% A dd i ti o na l C om pr e ss io n b ar 0

Crossings Costings Values (2010 basis) Index Cost summaryDefault User Units Default User Default User Value Units

Onshore - Road 0 Materials - steel pipe only m/km 0.16 RPI Pipeline capi tal cost (base) 746 m

Onshore - Pipel ine 0 Labour m/km 0.24 RPI

Onshore - O ther 0 Othe rcosts f or al l pi pe li nes m/km 0. 20 RP I P ipel ine capi tal cost ( scal ed for te rrai n 8 95 m

Of fs hore - P ipel ine 0 Offshore

Offshore - Other 0 Platform tie in m 48.0 EAndPCosts Opex cost fixed 18.8 m/a

Shallow Installation m/km 0.35 EAndPCosts Opex cost variable m/a

Heavy Lift m/km 0.02 EAndPCosts

Remote Control Dredging m/km 0.02 EAndPCosts

Default User Marine Survey m/km 0.02 EAndPCosts

Umbi lical 0 Transportation m/km 0.02 EAndPCosts

Umbilicals m/km 0.06 EAndPCosts

Trenching to beach m 22.0 EAndPCosts

Materials- coating/concrete m/km 0.17 RPI

Timing U n i ts D e f au l t U s erC on str uc ti on du ra ti on y ea rs 3

Operational year 2015Cease ope rati ons y ear

Pipeline Module 1

% of total length

Number

Number

Documents

Bos2 Chain Units Pipelines