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APPENDIX I
PIPELINE DESIGN DOCUMENT
Section
Description
Page
Foreword ..............................................................................4
1.0
Network Simulation...............................................................5
2.0
3.0
Pipe Grade..........................................................................12
4.0
5.0
6.0
Material Specification..........................................................19
Appendix A
Appendix B
Appendix C
Revised Design...................................................................31
Appendix D
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Foreword
The following following document outlines the stages that were followed in the
design of the pipe material to be utilized in the construction of the high pressure
gas main to be constructed in 2005.
This document was compiled by Utilities Kingston personnel and then forward to
Mark Wolnick, a consultant retained for peer review. Mr Wolnick was able to
provide a fresh point of view, not considered by internal staff that results in
material design changes that subsequently wil mean cost savings.
The revisions and correspondence from Mr Wolnick are attached to the original
document as appendixes.
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1.0
Network Simulation
The following is a brief summary of the items considered to arrive upon the size
of the main to be utilized in the proposed HP Distribution system.
A simulation of the proposed high pressure distribution system was created using
an arbitrary route.
Several scenarios were run through this simulation with the consideration that :
The peak hour was around 2150 mcfh, December 31, 1999 from 8 to 9
PM (from historical records)
It was decided to determine the pipe size at the minimum operating pressure
required to satisfy Queens requirements and provide sufficient backup to carry
the load of the existing distribution system in the event of a failure
When the model was run using NPS 8, the pressure leaving City Gate
needed to be at 600 psi and left no room for expansion.
With NPS 10 from city gate to Counter-Sir J.A. the take off pressure at 500
psi delivers 415 psi to Queens.
The following are solutions from the modeling scenarios that were created.
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2.0
Using NPS 10 seemed a favorable scenario until inquiries where made regarding
availability and cost of materials (future considerations).
The Discussions, and estimates where provided from several firms including:
Larry Myers from AF Hall Ltd. who provide several appurtanances including
valves and cathodic insulators.
Brian Smith of Williamson Industries, they supply Spherical Tees and other
fittings used for future modifications to the system.
Cliff Clarke, Enbridge gas Ltd. Enbridge provides us with some consulting and
perform work on our system, under our direction.
Estimates from the suppliers are attached with this and demonstrate that 10
fittings are more uncommon than 12 and as such are generally as or more
expensive and require a much greater delivery time.
Cliff felt that construction costs between 10 and 12 should not vary much as the
trench preparation and any remedial work is the same. He did state however that
12 would leave much room for future expansion and security if the existing HP
system need to be taken out of service. He was also concerned that if we
required the assistance of Enbridge crews as we have utilized frequently in the
last several years, because they do not use 10 pipe they would not have the
equipment to work on this main.
Phone conversations with representatives of steel manufacturers Bob Colum of
Stelco Inc in Hamilton and Alex Afaganis of the Camrose Pipe Company in
Camrose Alberta also left an uncomfortable feeling about the supply of 10 pipe.
Nothing in particular derogatory was said of the size rather just comments as to
the uncommonness of this size in Canada.
Following these conversations the network simulation was rerun with the same
criteria as before but utilizing 12 diameter main.
When the simulation was changed to NPS 12 from city gate to Counter-Sir J.A.
and the remaining NPS 8, the take off pressure only needed to be at 450 psi to
arrive at 400 at Queens as is demonstrated on the following graphic.
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3.0
Pipe Grade
Steel
S = Unknown
t = Schedule 20 6.4mm (0.250)
D = NPS 12 323.9mm
D = NPS 8 219.1mm
D = NPS 4 114.3mm
4 (Z662 4.3.2.5)
F = 0.8 (Z662 4.3.3.2)
L = 0.50 (Z662 4.3.3.3)
J = 1.00 (Z662 4.3.3.4)
T = 1.00 (Z662 4.3.3.5)
4137KPa = 80% of design pressure (Z662 10.11.4.4)
P = 4137
0.8
P = 5171 KPa = 755 PSI
The formulae for design pressure was utilized to determine the grades of pipes:
Design Pressure:
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4.0
The SMYS is the grade of the pipe in MPa and represents the specified minimum
yield strength of the material.
In order to be classified a distribution company without transmission pipelines in
the system:
The pipeline must operate with the forces exerted on the main
(hoop stress) at or below 30% of the SMYS (Z662 12.1.1, 12.1.2)
To determine the hoop stress on the main same factors as used in determining
the grade of the material must be known with the exceptions that:
Therefore:
Material:
Wall Thickness:
Nominal Wall Thickness:
Class Location:
Design Factor:
Location Factor:
Joint Factor Seamless Pipe:
Temperature Factor:
MAOP
Steel
t = Schedule 20 6.4mm (0.250)
tn=6.4mm
4 (Z662 4.3.2.5)
F = 0.8 (Z662 4.3.3.2)
L = 0.50 (Z662 4.3.3.3) (class location 4)
J = 1.00 (Z662 4.3.3.4)
T = 1.00 (Z662 4.3.3.5)
4.14 MPa=4110 kPa=600 psi
S = 359
D = NPS12 323.9mm
S = 241
D = NPS 8 219.1mm
Hoop Stress
Sh=PD
2tn
%SMYS
%=Sh * 100
S
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5.0
Coating Requirements
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6.0
Material Specification
With these factors known and with the assistance of the CSA Standards Z-245.102 Steel Pipe and Z-245.20-02 External Fusion Bond Epoxy Coating for Steel
Pipe the following specification for this project can be generated:
1. Bare Steel Line Pipe
(i)
The bare steel line pipe shall be manufactured and tested in accordance
with the requirements outlined in CAN/CSA Z245.1-02 and subsequent
revisions.
(ii)
The NPS 12, Schedule 20 pipe shall be 323.9mm outside diameter, grade
359, category I pipe with 6.4mm wall thickness.
The NPS 8, Schedule 20 pipe shall be 219.1mm outside diameter, grade
241, category I pipe with 6.4mm wall thickness.
The NPS 4, Schedule 40 pipe shall be 114.3mm outside diameter, grade
241, category I pipe with 6.0mm wall thickness.
(iii)
(iv)
The pipe shall be delivered in 15.0m lengths with plain ends, bevelled to
30o and all burrs removed.
2.
Exterior Coating
(i)
The exterior of the bare steel pipe shall be Fusion Bonded, Epoxy Coated
and tested in compliance with the requirements of CAN/CSA Z245.20-02
and subsequent revisions.
(ii)
The nominal thickness of the coating shall be 300m and no more than 1
test specimen per pipe length shall exceed 325m.
(iii)
The pipe shall be kept free of any coating materials for a distance of
150mm from both ends.
(iv)
The test temperature for the flexibility test shall be in accordance with the
powder manufacturers specifications (-30, -18 or 0 C).
(v)
The outside of the coated pipe shall be clearly and indelibly marked in
accordance with the requirements CAN/CSA Z245.1-02 section 15 and
CAN/CSA Z245.20-02 section 9. In addition to these requirements, the
markings shall also include Utilities Kingston Natural Gas Pipe.
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Appendix A
Peer Review
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Therefore, the selection of NPS 12 for the City Gate to Counter Street section, and
NPS 8 for the remaining portion of the pipeline, is appropriate as proposed.
3.0 & 4.0 Pipe Grade Selection and Hoop Stress
The factors identified to calculate grade of pipe and hoop stress levels for the
proposed HP pipeline conform with CSA Z 662-03 Oil and Gas Pipeline Systems
standard.
The following observations regarding the determination of the design factors are
offered;
Class Location
Class location 4 is appropriate in view of the expected development along the
pipeline route. A case could be made for Class 3 along the northern section of the
NPS 12 pipeline route, however it would not materially effect the design selection of
pipe and fittings.
Railway Crossings
Any railway crossings should be identified along the pipeline route. Method of
crossing should be determined (cased or uncased) and pipeline design and pipe grade
confirmed compliant with Sec 4.8.3 and Table 4.10 & 4.11 of Z662-03.
Pipe Wall Thickness
As stated in the document, the pipe wall thickness 0.250 inches (6.4mm) was selected
since it is typical of the pipes in the Utilities Kingston distribution system. While the
selection based on past practices may prove to be appropriate, other standard wall
thickness corresponding to alternative pipe grades should also be evaluated. This will
determine the most practical and economic design that conforms with distribution
pipeline standards and addresses the conditions under which the pipeline is operating.
For example, some utilities will specify additional wall thickness as an allowance for
corrosion for pipelines operating in urban or built up areas that are intended to operate
at greater than 275 psig (1900kPa). This may be an allowance that should be
considered if history of corrosion or excavation damages on the distribution system
warrant.
MOP Selection
The reference to Z662 Sec 10.11.4.4 as the basis for deriving the MOP applies to
upgrading of existing systems where pressure testing is not practical. In the case of
the proposed HP pipeline hydrostatic testing will be done to 1.4 times the design
pressure of the pipeline.
The Maximum Allowable Operating Pressure of the pipeline is intended to be the
inlet pressure at the TCPL/City gate. This is 600 psig. (4140 kPa)- which will be the
design pressure. The Normal Operating Pressure of the HP pipeline is 450psig (3100
kPa).
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Pipe
Diameter
NPS 12
NPS 8
3800 kPa
NPS 12
NPS 8
Wall
mm
6.4
7.1
6.4
6.4
4.8
6.4
7.1
6.4
4.8
6.4
Grade
290
290
359
241
290
290
290
359
290
290
Hoop stress
% SMYS
36 %
33%
29%
29%
33%
33%
30%
27%
30%
22%
Recommendations
The following are recommendations regarding the HP pipeline design specifications:
The NPS 12 specifications should be based on a Grade 369 and 6.4 mm wall pipe,
unless history of corrosion and excavation damage warrants increasing the wall to
7.1mm.
Utilities Kingston should decide if the 600 psig (4140kPa) MAOP is critical to
future operation of the HP pipeline or if 550 MAOP (3800kPa) is acceptable to
meet future requirements.
If 600 MAOP is required (or can in fact be delivered at Counter St) the NPS 8
specification should be Grade 241 and a 6.4mm wall pipe.
If 550 MAOP is acceptable, the NPS 8 specification Grade 290 and a 4.8mm wall
pipe is recommended. This will result in a saving of approximately $120,000 for
the NPS 8 HP pipeline section based on comparative pipe costs for Grade 214
specified and Grade 290 recommended. (ref. Attachment 1).
Once final route selection is completed, pipe specifications for railway and road
crossings should be verified.
Submitted Nov.18/04
Mark A. Wolnik P.Eng
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Pipe
Diameter
NPS 12
NPS 10
NPS 8
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Grade
MPa
359
359
290
290
290
290
241
290
Wall
mm
7.1
6.4
7.1
5.6
9.3
7.1
6.4
4.8
Estimated
$ cost/m
84
76
83
55
90
56
50
38
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Appendix B
Internal Communications
From:
Sent:
To:
Sopha, Dale
Monday, November 22, 2004 10:24 AM
Sopha, Dale; Miller, Jim; Phippen, Chris; Quinn, Don; McIvor, Randy; Taylor,
Nancy
Subject:
RE:
The links that were in the previous E-mail are here
The report I created:
<file://\\Csw2k1\utsyseng\Projects\E11 Natural Gas\E11-14-2004 High Pressure Gas Main
Study\Pipe Specification.pdf>
The reply from Wolnick:
<file://\\Csw2k1\utsyseng\Projects\E11 Natural Gas\E11-14-2004 High Pressure Gas Main
Study\Utilities Kingston -HP Design Review from Wolnick.pdf>
_____________________________________________
From:
Sopha, Dale
Sent:
Thursday, November 18, 2004 1:10 PM
To:
Miller, Jim; Phippen, Chris; Quinn, Don; McIvor, Randy; Taylor, Nancy
Subject:
28 of 35
29 of 35
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Appendix C
Revised Design
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NPS 12
NPS 8
323.9 mm
6.4 mm
API 5LX52-359Mpa
CSA Z245.1 Cat. 1
CSA Z245.1 Cat.1
CSA Z245.20(External Fusion
Bond) or Z245.21 Yellow
Jacket
CGA OCC-1
CSA Z245.11
CSA Z245.12
CSA Z245.15
4
1.20 m
3,800 kPa
219.1 mm
4.8 mm
API 5LX52-290Mpa
CSA Z245.1 Cat. 1
CSA Z245.1 Cat.1
CSA Z245.20(External
Fusion Bond) or Z245.21
Yellow Jacket
CGA OCC-1
CSA Z245.11
CSA Z245.12
CSA Z245.15
4
1.20 m
3,800 kPa
27% SMYS
3,100 kPa
29.5% SMYS
3,100 kPa
22% SMYS
5,300 kPa
24% SMYS
5,300 kPa
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Appendix D
Revised Specification
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