Documente Academic
Documente Profesional
Documente Cultură
FOR
NIGERIAN SOCIETY OF ENGINEERS (NSE)
MEMBERSHIP EXAMINATION
(DECEMBER, 2015)
BY
JOHN MARK
ABSTRACT
This report summarized the engineering experience of the author for the membership examination
of the Nigerian Society of Engineers (NSE) in April 2013.
Introduction chapter introduced the profile of the author and the purpose of the document.
Chapter one summarized the detail of “Design of gas supply pipeline to PHCN Delta IV”.
Chapter two focused on “Design of fire water spray system for the pressure reduction and metering
station of PHCN Delta IV”.
Chapter three summarized the project report of “Compressed Natural Gas Mother Station (CNG)
Engineering, Procurement and Construction”
The report of the project in each of the main chapters (1, 2 and 3) contained: title of the project,
statement of the problem, solution provided, problems encountered, conclusion and
recommendation.
In each of the projects reported, the objectives of carrying out the exercise were fully met. For the
“Design of gas supply pipeline to PHCN Delta IV” a 20 inches, Schedule 40, API 5L X 65(Grade
B), Carbon Steel Pipe was the final design. A fire water spray system was successfully designed
based on the “Single Fire Risk” for the PHCN Delta IV PRMS. For the Compressed Natural Gas
Mother Station (CNG) Engineering, Procurement and Construction, the objective was met in three
phases. The first part involved successful management of the remaining design phase. The second
part involved managing the scheduled construction work for the period. The third section involved
successful management of delivery of the procured equipment skid to Nigeria from Italy
TABLE OF CONTENTS
ABSTRACT ................................................................................................................................... 2
INTRODUCTION......................................................................................................................... 6
CHAPTER ONE: DESIGN OF GAS SUPPLY PIPELINE TO PHCN DELTA IV ............ 10
1.1 Statement of the Problem .................................................................................................... 10
1.2 Design Solutions ................................................................................................................. 10
1.2.1 Understanding of the design problem and gathering of basic design data ................... 11
1.2.2 Codes and Standards ..................................................................................................... 12
1.2.3 Options for pipe sizing ................................................................................................. 12
1.2.4 Sizing of pipe ................................................................................................................ 13
1.2.5 Calculation of pipe wall thickness ................................................................................ 14
1.2.6 Calculated External Pipe Diameter............................................................................... 15
1.2.7 Recommended Pipe ...................................................................................................... 15
1.2.8 Transportation simulation and hydraulic studies .......................................................... 15
1.3 Problems Encountered ........................................................................................................ 16
1.4 Conclusion .......................................................................................................................... 17
1.5 Recommendation ................................................................................................................ 17
CHAPTER TWO: DESIGN OF FIRE WATER SPRAY SYSTEM FOR THE PRESSURE
REDUCTION AND METERING STATION (PRMS) OF PHCN DELTA IV .................... 18
2.1 Statement of the Problem .................................................................................................... 18
2.2 Design Solutions ................................................................................................................. 18
2.2.1 Fire outbreak assumption.............................................................................................. 19
2.2.2 Design Basis: Fire water demand ................................................................................. 19
2.2.3 Fire water source ........................................................................................................ 19
2.2.4 Fire water pressure........................................................................................................ 19
2.2.5 Fire pump system.......................................................................................................... 19
2.2.6 Looping ......................................................................................................................... 21
2.2.7 Criteria for above and underground network ............................................................... 21
2.2.9 Protection for underground pipelines ........................................................................... 21
2.2.10 Protection for above ground pipelines ........................................................................ 22
2.2.11 Sizing of fire water distribution ring main ................................................................. 22
2.2.12 Friction loss calculation in water distribution pipe .................................................... 23
2.2.13 Pipe support ................................................................................................................ 24
2.2.14 Fire hydrants ............................................................................................................... 24
2.2.15 Monitors...................................................................................................................... 25
2.2.16 Fire Hose Boxes.......................................................................................................... 26
2.3 Problems Encountered ........................................................................................................ 26
2.4 Conclusion .......................................................................................................................... 26
2.5 Recommendation ................................................................................................................ 27
CHAPTER THREE - COMPRESSED NATURAL GAS MOTHER STATION (CNG)
ENGINEERING, PROCUREMENT AND CONSTRUCTION (EPC) ................................. 28
3.1 Statement of the problem .................................................................................................... 28
3.2 Solution Provided................................................................................................................ 29
3.3 Problems encountered ......................................................................................................... 29
3.4 Conclusion .......................................................................................................................... 30
3.5 Recommendation ................................................................................................................ 30
INTRODUCTION
John Mark graduated from Ladoke Akintola University of Technology (LAUTECH) Ogbomoso
in 2006 with a second class upper grade in Chemical Engineering. He has since then involved in
engineering project delivery. He first worked with Scanpin Computers in Sango Ota, Ogun State
between 2007 and 2009. He later joined the workforce of San Miller Limited Abuja office as a
Process and Technical Support Engineer in 2009. San Miller Limited is an engineering consulting
firm with over 25 years’ project experience in engineering design and process simulation
consultancy in oil and gas sector. In 2012 he became a Process/Project Development Engineer in
respond to the need of San Miller Limited. He was seconded as Project Manager to Ener-Gas
International Investment Limited in September 2012 for a period of four months to manage
engineering, procurement and construction of a compressed natural gas mother station. He
returned back to San Miller in January 2013 to retain his position as a Process/Project Development
Engineer.
As a Process and Technical Support Engineer, Mark was involved in process design for oil and
gas production facilities. He also offered product training on Aspen One Engineering (A suite of
process simulation software products sold by San Miller Limited on behalf of its owner – Aspen
Technology Incorporated in Nigeria).
Mark in the last six years has been involved in the following engineering projects:
III. Project Management Planning Consultancy Service Gas Supply Pipeline Delta IV
(Procurement and Construction Phases)
Type of Project: Project management consultancy
Project Position: Project Engineer
Client: Federal Ministry of Petroleum Resources
IV. Design of Fire Water Spray System for the Pressure Reduction and Metering Station
(PRMS) of PHCN Delta IV
Type of Project: Front End Engineering Design (FEED)
Project Position: Process Engineer
Client: Federal Ministry of Petroleum Resources
Mark has undergone various local and international trainings such as:
Mark was certified as a Project Management Professional (PMP) by Project Management Institute
(PMI) in 2012.
This report summarized the engineering experience of the author for the membership examination
of the Nigerian Society of Engineers (NSE) in April 2013.
Introduction chapter introduced the profile of the author and the purpose of the document
Chapter one summarized the detail of “Design of gas supply pipeline to PHCN Delta IV”.
Chapter two focused on “Design of fire water spray system for the pressure reduction and metering
station of PHCN Delta IV”.
Chapter three summarized the project report of “Compressed Natural Gas Mother Station (CNG)
Engineering, Procurement and Construction”
The report of the project in each of the main chapters (1, 2 and 3) was written in this format:
The Federal Government of Nigeria in pursuit of the desire to generate sufficient electricity power
to meet the demand of the country decided to develop a pipeline to supply natural gas to the Power
Holding Company of Nigeria (PHCN) power plant located at Ughelli area of Delta State.
The proposed pipeline was meant to start at a point on the Escravos Lagos Pipeline (ELP) and
terminated at a proposed processing facility in Ugheli. The length of the pipeline has already been
established by survey to be 3.6 km.
This engineering design study was established to recommend a suitable pipe (with adequate size,
wall thickness and other necessary properties) for the transportation of 300MMSCF/D of natural
gas from the tie-point to the processing facility. The study was also meant to carry out
comprehensive transportation simulation or hydraulic studies to:
Analysis of results
Reporting
1.2.1 Understanding of the design problem and gathering of basic design data
Detailed analysis of the design problem based on the available information revealed that the gas
pipeline is a transmission line.
The basic designed data obtained from the client and Nigerian Gas Company (NGC), the operator
of ELP is presented below:
Composition Mol %
C1 81.64
C2 5.91
C3 3.77
iC4 1.24
nC4 1.18
C5+ 1.60
H2S -
N2 0.69
CO2 3.97
TOTAL 100.0%
At this level of the project, pipe was considered to be sized based on pressure drop. Velocity
allowance would be considered later during transportation simulation and hydraulic studies.
During the course of this project, various mathematical models for calculating pressure loss in gas
were suggested for sizing this pipe. The suggested models were:
Weymouth equation
Panhandle A equation
Panhandle B equation
Spitzglass equation
Weymouth equation has limitations with respect to this type of flow. Its accuracy was limited to
sizing of short pipe within a production facility whose gas pressure fell below 450kPa. Also the
gas velocity and the Reynolds number (Re) must be low and the flow must be laminar before it
can be used. Since the operating pressure of this gas was above 450kPa and the line was
transmission type (3.6km) with high tendency of turbulent flow (Re > 2000) Weymouth equation
was disqualified.
Spitzglass equation also has limitations with respect to this type of flow. It usually gave misleading
results for pipe diameters over 10 inches. Since the gas throughput expected to flow through the
pipe was high, there is high tendency of having pipe diameter greater than 10 inches hence
Spitzglass equation was disqualified.
Panhandle A and Panhandle B equations were the best options for sizing the pipe at hand. The two
models were developed for large-diameter, long-pipelines with high-pressure. Both Panhandle
equations are dependent on Reynolds number but the Panhandle B is less dependent than the
former because it included implicit values for pipe roughness for each diameter to which it is
applied which makes it (Panhandle B) to be considered for this sizing.
Where
L = Length (mile)
Q = 300 MMSCF/D
The pipe wall thickness was calculated based on the steel pipe design formula of ASME B
31.8, paragraph 841.11, based on design pressure (100 barg = 1470 psig).as given below:
𝟐𝒔𝒕
𝑷= 𝑭𝑬𝑻 (1.2)
𝑫
Where
D = Pipe outer diameter = (18 + 2t) in. (Note “t” is the pipe wall thickness)
S = Specified min. yield strength = 65,000 psi (as per API 5L X 65)
F = Design Factor = 0.5 (Considering the available survey data and future development potential
of the areas forming the pipeline route, Location Class 3 has been selected for the pipeline design
owning to the long life design criteria by the client and the fact the town is rapidly developing.)
After determining the pipe wall thickness that meets mechanical requirements, such as pressure,
temperature and weight of equipment, an extra thickness called "corrosion allowance” was added
to the pipe wall thickness to compensate for the metal expected to be lost over the life of the
equipment.
Based on requirement DPR and Nigerian Gas Company (NGC), 3mm corrosion allowance was
recommended. However in view of the long life span (25 years) proposed for this pipeline, a safety
factor of 2mm was further added to the recommended corrosion allowance which put it at 5mm.
Based on the velocity limitation, 20 inch, schedule 40, carbon steel pipe was found appropriate for
the desired throughput at all considered operation conditions.
The outlet gas from the pipeline at all operation conditions considered could not meet the pressure
requirement of 30barg which necessitated a need for pressure reduction station.
Based on standard practice and the need to ensure that the gas is free of unwanted particles and
liquid, a filter separator was proposed as the first unit in the pressure reduction facilities.
Next to the filter separator, pressure reduction unit was proposed to reduce the pressure of the
filtered gas to 30barg but after simulation studies it was discovered that the outlet fluid was a gas-
liquid mixture which cannot be used for power generation. A heater was then proposed to preheat
the filtered gas before it enters the pressure reduction which the simulation material and energy
balance confirmed appropriate. The preheating eliminates the tendency of hydrate formation and
multiphase flow throughout the facilities.
i. Filter separators
ii. Liquid handling facilities
iii. Heating system
iv. Pressure reduction unit
v. Gas metering unit
Government bureaucracy which affected the project schedule. This was addressed by
working sometime on Saturday.
Hindrance from project host communities to gain access to site. A better community
relation approaches were formulated to take care of that
1.4 Conclusion
The major objective of this project was to recommend a suitable pipe (with adequate size, wall
thickness and other necessary properties) for the transportation of 300MMSCF/D of natural from
the tie-point to the processing facility and to propose units for the pressure reduction facilities.
This objective was met in three phases. The first part involved sizing of pipe based on modified
Panhandle equation (a pressure loss model) to determine the best internal diameter for the pipe.
The second part involved determining the pipe wall thickness based on mechanical requirements
and corrosion allowance. The third section involved comprehensive transportation simulation and
hydraulic studies to confirm the calculated pipe size, confirm possibility of hydrate formation and
multiphase flow at any point of the pipeline, produce material and energy balance for the pipeline
network and propose process route for the processing facility that will treat the gas to desired
specifications.
Conclusively, a 20 inches, Schedule 40, API 5L X 65(Grade B), Carbon Steel Pipe was the final
design.
1.5 Recommendation
Additional flow assurance studies should be carried for the entire length of the pipe
Further studies should be carried out to confirm the corrosion allowance considered in the
design
CHAPTER TWO: DESIGN OF FIRE WATER SPRAY SYSTEM FOR THE PRESSURE
REDUCTION AND METERING STATION (PRMS) OF PHCN DELTA IV
Hydrants and
Monitors.
This engineering design study was established to select and size the main units of the system. The
study was also meant to carry out hydraulic calculation for the water distribution network.
The effective capacity of the tank above the level of suction point was designed for 4 hours
working capacity of pumping system.
The fire water network was design to be kept pressurised by a jockey pump which will maintains
the system pressure at 7 barg by starting and stopping automatically based on the system pressure.
The fire pumps was designed to deliver fire water at minimum of 7 barg at the hydraulically most
remote monitor or hydrant with the largest fire water requirement in the biggest area.
In line with codes and standards requirement, the fire water pumps consist of two (2) main pumps
(2 Diesel engine driven centrifugal pumps) with each pump being able to provide at least 100 %
of the maximum fire water requirement. Assuming one fire pump accidentally fails when called to
operate; the other pump can come in. Each of the two pumps was proposed to be horizontal
centrifugal type.
There would also be in addition, a jockey pump with a minimum capacity of 16 m3/hr (3% of the
design fire water rate) and maximum capacity of 53 m3/hr (10% of the design firewater rate) and
a minimum discharge pressure of 9 barg (which is 2 bar above minimum fire water pump discharge
pressure at the hydraulically most remote monitor or hydrant.)
The specification of fire water pump summarized as described in the table below:
Rated
Rated
S/N Service Type Capacity Head Driver
(m³/h) (barg)
Centrifugal Diesel
1 Fire Water Pump (Duty) 636 13
Horizontal Engine
Centrifugal Electric
3 Jockey Pump 53 13
Horizontal Motor
Fire Water Pumps, Drivers and Controllers were proposed to be installed in the Fire Pump House,
which was decided to be located in the safe area (non hazardous area).
The main fire water pump shall be provided with automatic starting facilities which will be
activated for any of the following causes:
When the fire water ring main pressure is lower than 7 barg at the hydraulically most remote
monitor or hydrant
Local manual start (Local control panel)
The fire water ring main pressure was designed to be always maintained by the jockey pump that
could start automatically when the fire water header pressure is low (below 7barg) and stop when
the fire water header pressure is high (above 7barg).
For any reason, if the fire water ring main pressure falls down below 7 barg the duty fire water
pump was designed to start automatically. When the duty fire water pump failed to start or not
able to develop the required minimum pressure of 7 barg at the most remote point, the standby
pump was designed to start automatically.
Pumps can also be started manually from the pump local control panel. The only way for the
operator to shutdown the fire pumps would be by pressing the local stop push button.
2.2.6 Looping
The fire water network was designed to be laid in closed loops as far as possible to ensure multi-
directional flow in the system.
Isolation valves were proposed to be provided in the network to enable isolation of any section of
the network without affecting the flow in the rest as shown in the attached Plot Plan.
The Isolation Valves was proposed to be gate valves made of cast steel.
1. Road crossings
2. Places where the above ground piping could likely to cause obstruction to operation and
vehicle movement, and get damaged mechanically.
3. In case of poor soil conditions it was recommended that concrete supports be provided
under the pipe.
Using the basic pipe flow equation (Q = VA). This equation was converted to normal units of
measure, as well as using the inside pipe diameter. The new equation later used was:
𝑸 = 𝟐. 𝟒𝟒𝟖 × 𝒗 × 𝒅𝟐 (2.1)
Where:
2799.7 = 2.448 × 10 × 𝑑2
d = 11 in.
𝟒.𝟓𝟐𝑸𝟏.𝟖𝟓
𝒑 = 𝑪𝟏.𝟖𝟓 𝒅𝟒.𝟖𝟕 (2.2)
Where:
p = frictional resistance in psi per foot of pipe
Q = flow in gpm (gram per minute)
C = friction loss coefficient
d = actual internal diameter of pipe in inches
For the pipe distribution (based on fire water spray system plot plan), a friction loss is calculated
as follows:
Q = 2799.7 gpm
C = 120
d = 12inch
4.52(2799.7)1.85
𝑝=
(120)1.85 (12)4.87
27 × 4 × 0.00852 = 0.92𝑝𝑠𝑖
For 8 gate valves each with equivalent pipe size of 6ft, friction loss (p) is calculated as:
8 × 6 × 0.00852 = 0.41𝑝𝑠𝑖
For 8 Tee or cross (flow turned 90°) each with equivalent pipe size of 60 ft, friction loss (p) is
calculated as:
8 × 60 × 0.00852 = 4.1𝑝𝑠𝑖
Total friction loss along the pipe network = (9.78+ 0.92 + 0.41+ 4.1) psi = 15.21psi = 1.03bar.
Piping was designed to be supported by a concrete bases that will rise up to 300m above the ground
at 15ft from each other.
4 (four) number of hydrant is selected for this system based on hazardous area considerations as
shown in the Plot Plan for Fire Water System (Appendix 1).
All fire hydrants were proposed to be able to deliver 100% of the fire water requirement (530m3/hr)
at its outlet at 7 barg.
One fire hydrant was 6in. (150 mm) type with a single hydrant valve. One 4in. (100 mm) and two
2 1/2in. (65 mm) outlets with chained caps.
Other Specification
Material : Body ASTM A 106 Grade-B, Cap ASTM A 105, Chain SUS 304,
Valve B.C.6
2.2.15 Monitors
Monitors was deigned to be located at strategic locations for protection of cluster of filters, heaters,
etc.
Each of these monitor connections would be provided with independent isolation valves so that
the area the monitor is protecting can be isolated from the remainder of the station in case of an
emergency.
Monitors would be located to direct water on the object as well as to provide water shield to
workers approaching a fire.
The monitors would not be installed less than15 metres the equipment cluster.
Water monitors would have a straight stream range of at least 55 m in still air conditions at the
normal water operating pressure with a flow rate 530 m3/hr at 7 barg.
Other specification
Type: Fixed water monitor
Design Pressure: 13 barg (188 psi)
Isolation Valves: Gate valves made of Cast Steel.
2.2.16 Fire Hose Boxes
Fire Hose boxes are generally provided for the storage of fire hoses and nozzles to enable easy
access during fire emergencies.
Hose boxes (cabinets) were proposed to be located in the fire storage section of the security shed
of the PRMS. They are proposed to be manufactured of steel and be of the self standing type,
colored red, and have air vents in the side panels and lockable doors with a key in a glass fronted
box located on the side of the cabinet itself. They are designed to stand on legs. The base would
have a suitable drain hole at its lowest point.
Government bureaucracy which affected the project schedule. This was addressed by
working sometime on Saturday.
Hindrance from project host communities to gain access to site. A better community
relation approaches was developed to take care of that
2.4 Conclusion
The project was meant to select and size the main units of the fire water spray system. The study
was also meant to carry out hydraulic calculation for the water distribution network.
This objective was met in three phases. The first part involved selection of main units. The second
part involved sizing of the units. The third section involved hydraulic calculation for the water
distribution network.
Conclusively, a fire water spray system was designed based on the “Single Fire Risk” for the
PRMS.
2.5 Recommendation
Additional hydraulic analysis for the water distribution network involving use of
simulation software such as PIPENET software suite should be carried out.
Further structural and mechanical engineering design studies to confirm mechanical and
structural part of the project should be carried out.
CHAPTER THREE - COMPRESSED NATURAL GAS MOTHER STATION (CNG)
ENGINEERING, PROCUREMENT AND CONSTRUCTION (EPC)
Oando Gas & Power Limited (OGP) awarded an Engineering, Procurement and Construction
(EPC) project to Ener-Gas International Investment Limited to develop Compressed Natural Gas
(CNG) Mother Station (CMS) along Oshodi-Apapa Express Way in Lagos for the supply of natural
gas through tube trailers to consumers away from the existing gas pipeline network and also for
vehicular usage.
The expected output capacity of the plant is 150,000 Standard Cubic Meter per Day (SCMD) at a
discharge pressure of 250 barg.
6 inches, 100m spur line from the existing 8” dia. main distribution network along Oshodi-
Apapa Express Way.
Pressure Regulating and Metering Skids (PRMS) for the CMS and the Power generation
units.
Utility systems
The author was involved in managing the project for a period of four month as a project manager.
3.2 Solution Provided
As the project manager, the author performed the following responsibilities:
Handling invoicing
Working with project sub contractors to develop project management plan; maintain scope,
time and cost; and review and approve work/deliverables.
Developing project risk management plan, identifying possible risk factors and proposing and
executing appropriate mitigation.
Failure of the previous project management team to apply sound project management
practices to the management of the project activities. This was addressed by re-planning
from the period the author took over. The new plan was fully deployed for the project.
Missing design information which was addressed by engaging fresh design engineers to
redesigning the missing design packages.
3.4 Conclusion
The major objective of this project was to develop downstream facilities for the supply of natural
gas through tube trailers to consumers away from the existing gas pipeline network.
This objective was met in three phases. The first part involved successful management of the
remaining design phase. The second part involved managing the scheduled construction work for
the period. The third section involved successful management of delivery of the procured
equipment skid to Nigeria from Italy.
3.5 Recommendation
Sound project management practices should be deployed at all stages of project lifecycles.
Comprehensive checklist should be developed at planning stage of project to ensure all
work packages are adequately completed at scheduled time.