DBM_Margarita Pipeline Rev # 2 FINAL June 30th

Margarita Pipeline Project

MARGARITA EPF PROJECT

Flow Line & Export Pipelines

Basis of Design Memorandum

Prepared by :

Consorcio

ICBA

Santa Cruz, Bolivia

July, 2003

TABLE OF CONTENTS

Section No.Title

Tab No.

1.0

Introduction

1

1.1 Project

1.2 Location

1.3 Project Number

1.4 Owner

1.5 Client

1.6 Project Description

2.0

Basis of Design

2

2.1 Client Furnished Data and Assumptions

2.2 Applicable Codes and Standards

3.0

Methodology

3

3.1 Pipeline Route Location

3.1.1 Pipeline Corridor

3.1.2 Buildings Intended for Human Occupancy

3.1.3 Locations Classes

3.2 Line Lengths

3.3 Right-of-Way and Trench

3.4 Line Sizing

3.5 Wall Thickness Formulae

3.5.1 Line Pipe Cross Country

3.5.2 Railroad and Road Crossing Pipe

3.5.3 River Crossing Pipe

3.5.4 Charpy Values

3.6 Field Bends

3.7 Weld Bevels

3.8 Blowdown Sizing

3.9 Mainline Valve Setting

3.10 Scraper Traps

3.11 River Crossing Location and Design

3.12 Wet Land Area Design

3.13 Meter Stations

3.14 Pressure Alert Valve

3.15 SCADA System

3.16 Cathodic Protection and Monitoring System

3.17 Hydrostatic Test

Section No.Title

Tab No.

4.0

Calculation Results

4

4.1 Location Classes and Design Factor, F

4.2 Line Lengths

4.3 Line Sizing

4.4 Wall Thickness Formulas

4.4.1 Maximum Allowed Operation Pressure


4.4.3 River Crossing Pipe Wall Thickness

4.4.4 Calculated Charpy Valves

4.5 Weld Bevels

4.6 Blowdown Sizing

4.7 Mainline Valve Settings

4.8 Scraper Traps

4.9 River Crossing Design

4.9.1 Major River Crossings

4.9.2 Minor River Crossings

4.9.3 Creek Crossings

4.10 Wetland Areas

4.11 Meter Stations

4.12 Pressure Control

4.13 SCADA



5.0 Design Data and Calculations

5

Hydrostatic Calculations

MAWP Pipe

Blowdown Sizing

Stresses in Road Railroad Crossing Pipe

Buoyancy Calculation for wetlands

Ultrasonic Meter Flow rates

Control Valve Sizing

Minor River Scour Calculations|

LIST OF EXHIBITS

Section No.Title

Tab No.

1a

Preliminary Pipeline Location (Original Route)

6

1b

Preliminary Pipeline Location (Alternative # 1)

6

( As per Commercial Document )

2

Surveyed Route

6

3

Pipeline Schematic

6

4a

Right of Way and trench

6

4b

Right of Way and trench

6

4c

Right of Way and trench for Wetlands

6

4d

Right of Way and trench for Wetlands

6

5

Design Flow Diagram

6

6

Weld Bevels

6

7

Typical Minor River Crossing

6

8

Typical Creek Crossing

6

9

Fill Water Pipeline Schematic Diagram

6

LIST OF TABLES

Table No.

Title

Tab No.

1 House Count and Location Classes Summary

7

2 Line Lengths

7

3 Hydraulic Calculations Results (Example Only)

7

4 Pipe MAWP vs. MAOP

7

5 Road and Railroad Crossing pipe

7

6 Mainline Valves Settings (Example Only)

7

7 Scraper Traps Location

7

BASIS OF DESIGN

1.0 Introduction

1.1 Project Margarita EFP Project - Flow Line & Export Pipelines

1.2 LocationMargarita Fields, South of Bolivia

1.3 Project Number

0670 8300

1.4 Owner/Client

MAXUS Bolivia Inc.Address:

Av. Jos Estensssoro # 100

Santa Cruz de la Sierra

Bolivia.

1.5 Client

-

Consorcio ICBA

Address:

Km. 3 Carr. Cbba Casilla : 3616

Telfono Piloto: 352 9270

Fax : 352 3713

Santa Cruz de la Sierra

Bolivia.

Management:

Project Director:

Mel Schulze

Cell Ph.:

(591) 716 - 88285

Ph.:

(591) 3 337 7282 / 352 - 9270

Fax:

(591) 3 337 7283 / 352 - 3713

Project Manager:

Jack Bogan

Engineering Manager: John Belew

1.6 Project Description

These is EPC Project, where plans the installation of a 8 5/8 O.D. Gathering System approximately 30.2 Km into its under construction Margarita EPF Gas Treating Plant Facilities. Gathering System Flow lines will commence at the existing wellheads, Margarita X1 and X3.

Also, plans the installation of the 6 5/8 O.D. liquid Exporting Pipeline approximately 54 Km length leaving its under construction Margarita EPF Gas Treating Plant Facilities and interconnecting at the delivery point to a 6 O.D. Oil Transmission Pipeline.

Also, include the installation of the 10 O.D. Gas Exporting Pipeline approximately 51 Km in length leaving its under construction Margarita EPF Gas Treating Plant Facilities and interconnecting at the delivery point to a Gas Transmission Pipeline. Both delivery point at the Hot Tap fitting connection.

2Basis of Design

2.1Furnished data and Assumptions

The following data furnished by MAXUS Bolivia Inc. and/or proposed by INTEC Engineering will be used as a basis of design:

Preliminary Pipeline Location Exhibits 1a & 1b.

Design Code ASME / ANSI B31.4 Pipeline Transportation System for Liquids Hydrocarbons and B31.8 Gas Transmission & Distribution Pipeline System.

Pipeline Diameters:

8.625O.D.6.625O.D.10.750O.D.

W.T. Grade

0.375 X600.280 X600.365 X60

0.500 X600.344 X600.500 X60

Design Pressure:

1.900 psi1.700 psi1.770 psi

Pipe Lengths:

Gathering Sys.

30 Km

Export Liquid Line

54 Km

Export Gas Line

51 Km

ANSI Class Rating:

1.500 lbs.900 Lbs.900 Lbs.

Corrosion Allowance:

3 mm.

3 mm.

3 mm.

Design Factor:

Location Class 10.72

0.72

0.72

River Crossing0.72

0.72

0.72

Fabrication 0.72

0.72

0.72

External Coating:

3 Layers coating Polyproplyene

Internal

None

Joint Coating:

Same as Yard Place Application.

Specify Gravity:

0.600

Standard Conditions:

Temperature

60 F

Pressure

14.73 psia

Rigth-of-Way Width:

15 meters Permanent

Block Valves:Full Opening Ball Type spaced to meet Code requirements

Meter Stations:Gas Meter is Multi-path Ultrasonic and Liquid Turbine

2.2 Applicable Codes and Standards

The last revision of all codes, standards, and applicable governmental regulations shall be followed except as modified to be more stringent by these criteria. Legal requirements shall have preference over these criteria unless the authorized legal authority grants an exception.

Unless otherwise noted, references made herein to codes, standards and specifications are to the latest edition.

ASME B31.4, Piping Transportation System for Liquids Hydrocarbons.

ASME B31.8, Gas Transmission and Distribution Piping Systems.

ASME B 31.3, Process Piping Section VII.

American Petroleum Institute, Specification for Pipeline Valves, End Closures Connectors and Swivels, API 6D.

American National Standards Institute, Steel Pipe Flanges and Flanged Fittings, ANSI B16.5

American National Standards Institute, Factory-made Wrought Steel Butt-Welding Fittings, ANSI B16.9

American Society of Mechanical Engineers, Boiler and Pressure Vessels Code, Section VIII, Pressure Vessels, Division 1.

American Petroleum Institute, Specification for Line Pipe, API 5L.

American Petroleum Institute, Recommended Practice for Railroad Transportation of Line Pipe, API RP 5L1.

American Petroleum Institute, Recommended Practice for Marine Transportation of Line Pipe, API RP 5L5.

American Petroleum Institute, Recommended Practice for Liquid Petroleum Pipeline Crossing Railroad and Highways, API RP 1102.

American Gas Association, Measurement of Gas by Ultrasonic Meters, Transmission Measurement Committee Report N 9.

National Corrosion Protection Engineering, Recommended Practice for Design of Underground Piping Systems, NACE-RP-69.

Manufacturers Standardization Society, Standard Marking System for Valves, Fittings, Flanges and Unions, MSS SP-25.

Manufacturers Standardization Society, Steel Pipe Line Flanges, MSS SP-44.

Manufacturers Standardization Society, Specifications for High Test Wrought Butt-Welding Fitting, MS SSP-75.

Manufacturers Standardization Society, Steel Valves Socket Welding and Threaded Ends, MSS SP-84.

American National Standards Institute, Manual of Petroleum Measurements Standards, Chapter 14, Section 3, ANSI/API 2530.

American Gas Association, Orifice Metering of Natural Gas, Reports Nos. 3 and 3A.

American Society for Testing and Materials, Fittings of Wrought carbon Steel and Allow Steel for Moderate and Elevated Temperature, ASTM A234.

American Society for Testing and Materials Standard Specification for Seamless carbon Steel Pipe ASTM-A106.

3Methodology

3.1 Pipeline Route Location

3.1.1Pipeline Corridor

The Gathering & Export Pipelines will be located in a corridor extending 500 meters each side of the pipeline location supplied by MAXUS Bolivia Inc.

A map showing the preliminary route location is included as Exhibits 1a and 1b.

Any pipeline relocation outside of this corridor will be submitted to MAXUS Bolivia Inc. for approval. Explanations for the recommended relocation are to given.

3.1.2 Buildings Intended for Human Occupancy

The numbers of the buildings intended for human occupancy in a zone 400 meters wide along the pipeline centerline will be determined by field investigation and will be plotted on the alignment sheets.

3.1.3 Location Classes

Gas pipeline will be divided into random sections of 1.5 Km. in length such that the sections will include the maximum number of buildings intended for human occupancy.

The location Class and Design Factor F will then be determined in accordance with ASME B31.4 & B31.8.

3.2 Line Lengths

The line lengths used in the preliminary design work were determined by scaling the lengths from the Owners furnished maps and adding a roughness factor to provide for bends and minor line changes. These lengths will be replaced by the slack chain surveyed distances as they become available.

3.3 Right-of-Way and Trench

The Right-of-Way and trench configuration proposed for the project is included as Exhibit 4a and 4b. The minimum cover depth for Normal Soil will be 0.80 meter except in rock and wetlands. For rock the minimum cover depth will be 0.45 meters, and for wetlands 1.5 meters from the top of the concrete coating pipe.

3.4 Line Sizing

Hydraulic calculations to confirm the 6; 8 &10 line sizes will be made using the American Gas Association (AGA) flow equation modified by the Colebrook-White transmission factor as showed below,

Where:

Q = Flow rate (MMSCFD)

T= base temperature (520 R)

P= base pressure (14.73 psia)

P= upstream pressure (psia)

P= downstream pressure (psia)

G = gas specific gravity ( air = 1.0 )

T= flowing gas temperature (R, R = F + 460)

Z= gas compressibility factor

L = pipe length (miles)

d = pipe inside diameter (inches)

F = transmission factor = 4 Log(3.71 d/K)

K= effective roughness (inches)

INTEC Engineering uses GASMOD Version 4.0, Gas Pipeline Hydraulic Simulation for Windows for gas flow calculation. Model scenarios for the Gathering & Export Pipelines will be made for the volumes, using the following parameters :

Pipeline Efficiency 98%

Pipe Burial Depth 1 meter

Gas Specific Heat Radio 1.29

Gas Specific Gravity 0.600

Maximum Gas Velocity 50 ft/sec

Base Temperature 60 F

Base Pressure 14.73 psia

Pipe Thermal conductivity 29 Btu/hr/ft/degF

Soil Thermal Conductivity 0.800 Btu/hr/ft/degF

3.5 Wall Thickness Formulae

3.5.1 Line Pipe

INTEC Engineering uses the Steel Piping Design Formula from ASME B31.4 & B31.8 to determinate the appropriate wall thickness and/or maximum allowable working pressure/design pressure of the line in accordance with ASME B31.4 & B31.8 requirements.

The formula is as follows:

P = F E T

Where:

P= Design pressure, psig

S=Specified minimum yield strength, psi.

Stipulated in the specifications under which the pipe was purchased from the manufacturer.

D= Nominal outside diameter of pipe, inches

T= Nominal wall thickness, inches

F= Design factor

E= Longitudinal joint factor

T= Temperature rating factor


API RP 1102 will be followed to determinate the minimum wall thickness for line pipe installed for railroad and road crossing.

INTEC Engineering uses PC-Pisces, personal Computer pipeline Soil Crossing Evaluation System to determinate the stresses on uncased pipe on crossings. Cornell University developed this software under the sponsorship of the Gas Research Institute. A flow diagram of the design procedure is included as Exhibit 4.


Wall thickness calculations for major river crossings will be based a Design Factor of 0.60. The pipe is to be manufactured by the sumerged arc process. Calculations will be based on river water with a specific gravity of 1.25. Consideration will be given to horizontal directional drilling the major river crossings.

Wall thickness calculations for minor river crossing will be based on a Design Factor of 0.72. The pipe is to be manufactured by the ERW process. Calculations will be based on river water with a specific gravity of 1.25. Special construction pipe provided with a continuous concrete coating will be used on the minor river crossing.

Regular line pipe will be used on the creek crossing. Concrete bolt-on weights to be installed where negative buoyancy is required or as instructed by the Company.

3.5.4 Charpy Valves

In detail design description in Project Execution Plan.

3.6 Field Bends

Large angle bends shall be broken down into several smaller angles to insure the maximum allowable bend per joint of pipe is not exceeded. The maximum field bend per joint of pipe shall not exceed 1- degrees per pipe diameter length after allowance for leading and trailing tangents required by bending machine. An internal mandrel will be specified for all field bends. All bends shall be located within the right of way. Wrinkle or mitre bends will not be allowed.

3.7 Weld Bevels

All joints will be designed for a 100% joint efficiency. Bevels and transitions will comply with B31.4 & B31.8 requirements.

3.8Blowdown Sizing

The following formula will be used for determining valve sizing for pipeline blowdown time:

T=

Where:

T= Blowdown time, minutes

P= Initial pipeline static pressure, psig

G = Specific gravity of gas

d = Inside diameter of blowdown riser, inches

L = Length of pipeline, miles

D = inside diameter of pipeline, inches

n = Number of risers blowing

F= Choke factor, depend of type of valve

Valves for F

F

Thru port Gate or Ball

1.6

Regular Gate

1.8

Plug Valve, Regular Pattern

2.0

Plug valve, Venturi Pattern

3.2

3.9 Mainline Valve Settings

Mainline Line Block Valves (MLVs) will be installed to meet ASME B31.4 & B31.8. Code requirements. The valves are to be full opening to permit the passage of scrapers. All valves will be gear operated.

Final locations of the MLVs will be field determined with due consideration to accessibility at intervals to meet code requirements.

3.8 Scraper Traps

Scraper traps will be installed at the beginning and terminal of each pipelines.

The scraper traps will be designed to handle an electronic inspection device (intelligent pig). The scraper barrel will be designed with extruded outlets and scraper trap assembly will be designed with a maximum design factor, F of 0.60.

Tees will be provided with guidebars.

3.9 River Crossing Location and Design

The design of the pipeline river crossings will consider the following activities:

Regime analysis

-Historical behavior of the channel, over a period, based on conditions of water and sediment discharge, width, depth, slope, meander form and progress and degradation of the riverbed.

Hydrology

-Estimate of Standard Project Storm (SPS). The Standard Project Storm estimate for the specific drainage area above the crossing and season of the year representative of should represent the most severe flood-producing rainfall depth-area-duration relationship.

-Estimate of Standard Project Flood (SPF) representing flood discharges that may be expected from the most severe combination of meteorological and hydrologic conditions that are considered reasonability characteristic of the geographical area, excluding extremely rare or unlikely combinations.

-Derivation of Project Design Flood (PDF) representing flood hydrograph or peak discharge value to be used as the basis for design after full considerations has been given to flood characteristics, frequencies, and potentialities, and the economics and continuity of service considerations and other practical considerations entering into the selection of the design discharge criteria.

-Delineation of the floodplain boundaries.

-Routing the SPF and/or the PDF through the stream crossing. All routing will use Mannings Equation:

Q = (A)(R)(S)

Where:

Q = Discharge in cubic feet per second

A = Area of flow in square feet

R = Hydraulic Radius A/WP in feet

WP = Wetted Perimeter

S = Slope of water surface in feet per foot

n = Manning roughness coefficient

Field Reconnaissance

Potential problem areas will be studied in detail including potential cutoffs, evidence of valley wall instabilities and crossing constructability.

Stream Surveys

Stream surveys consisting of:

-Floodplain bank and bed topography

-Vegetation and surface materials

-Observed high water levels at bank full and design flood conditions

-Longitudinal survey of channel noting water level and high water marks and minimum bed elevation

-Velocity and discharge at the crossing section

-Particle size distribution of bed and bank material samples

-Core samples and river bed analysis at crossing site

Channel Hydraulics

Depth of scour will be calculated by using Blenchs equations for regime depth:

d =

Where:

Q = = Unit discharge

d= regime depth

b = channel breadth

F= bed factor = F( 1 + 0.12C )

F= zero bed factor

C = bed load charge

The value of F is determined from one of the following equations (whichever is greater):

F= 48

or

F= 7.3 D

Where:

d = maximum depth of water below design water surface.

D = Median particle size

Scour depth, d = Z x d

Z= Values for Estimation of Scour Depth

Conditions

PDF

Bankfull

Forced Ridig Bend

1.4 2.50

1.4 4.0

Free Eroding Bend

1.4 1.75

1.4 2.5

Confluence

1.5 2.00

2.0 3.0

Obstruction

1.75 2.50

2.5 4.0

Impinging Flow

1.75 2.50

2.5 4.0

Depth of Pipe

d= d+ d+ S

Where:d= depth of top pipe from the design water surface.

d= depth of scour from the design water surface.

d= channel degradation due to downstream channel cutoff, or washing out or rapids downstream of the crossing.

S= a safety margin which may be required to account for uncertainties in the data.

Bank migration potential

Factor to be considered are:

-The down-valley shifting of the meander pattern

-The potential for a downstream cutoff

-Bank material composition

-Bank vegetation

-Natural protrusions or man-made work in the vicinity of the pipeline crossing

-The presence of bedrock

-Width of the valley

3.10 Wetlands Area Design

A special design will be used for all the wetlands areas in order to provide sufficient pipeline negative buoyancy and to mitigate damage to the environment.

3.11 Meter Stations

Gas Meter is Multi-Path Ultrasonic and Liquid is Turbine will be installed at terminal of each pipelines.

The metering station will be designed including ultrasonic meter runs sized to measure the volumes and pressures.

The design shall comply with AGA Report No. 9 Measurement of Gas by Ultrasonic Meters.

Isolation valves upstream of the meter shall be full opening and self-sealing. Piping will be sized for a maximum velocity of 2,500 feet per minute utilizing the following formulas:

A =

Where:

A = Cross sectional area of pipe in square feet

Q=Gas volume in cubic feet per minute at flowing temperature and pressure.

Q= x x x Z

V = Linear Gas Velocity

Q =Gas volume in cubic feet per day at base temperature and pressure

1440 = Number of minutes per day

T= Base temperature in R = 520 R

P= Base pressure = 14.73 psia

P= Flowing pressure in psia

Z = Gas compressibility factor

The following formula will be used to calculate the maximum capacity at reference (base) conditions for ultrasonic meters:

Q= Qx

Where:

Q= flow rate at reference conditions (Scfh)

P= absolute pressure at reference conditions (psia)

T= absolute temperature at reference conditions (R)

Q= flow rate at operating conditions (cfh)}

P= absolute pressure at flowing conditions (psia)

= absolute temperature at flowing conditions (R)

Z= compressibility of gas at flowing conditions

Z= compressibility of gas at reference conditions

3.12 Pressure Alert Valve (PAV)

Pressure Alert Valve (PAV) will be sized and installed at terminal of each pipeline to protect plant from overpressure. Each PAV will have a monitoring valve, which will be set at a difference range than the PAV and will operate only when PAV fails to alert the pressure to meet delivery requirements.

The valve sizing will be done using the following formula:

Q = x CPSIN

EMBED Equation.3 Where:

C= C/C

C= gas sizing coefficient

G = gas specific gravity

P= valve inlet pressure, psia

P = pressure drop across the valve, psi

T = absolute temperature of gas at inlet, deg. Ranking.

3.13 SCADA System

A SCADA System for the acquisitions of measurement data will be designed utilizing flow computers, Radio Modem and Fiber Optic Cable, and will be controlled and monitored from the central control room. The Radio Modem and Fiber Optic Cable will be installed at each meter run location where no other means of communication is available.

The SCADA system will be consistent with the system to be used in the main line.


A Cathoric Protection (CP) System will be designed and located according to the results of soil resistivity survey. The system will consist of rectifiers, anode beds, test leads, and insulated flanges. Rectifiers will be solar powered.

Insulated joints are to be installed at strategic locations to allow segmenting of CP system and allow isolation of above ground and connected facilities from the mainline CP system.

A grounding cell consisting of two zinc anodes will be installed at each insulated joints to reduce danger shock, arcing and burning of insulating material due to lightning.

Project design drawing will show the type and location of all cathodic protection test stations to be installed.

Test stations will be installed, where possible, in areas that are reasonably accessible to collect test data. Property or ownership boundaries will be the generally preferred locations.

Test Stations will be installed at intervals of two kilometers. The test stations installed at specific locations as outlined below will be counted toward achieving this spacing.

SPECIFIC LOCATIONS

-Type A, current test taps will be used at unusual locations such as cathodic protection rectifiers and at foreign line crossing where interference may be expected.

-Test stations will be installed at the following locations to the extent practical.

-At public road crossing, cased or uncased, and railroad crossing.

-At crossing of foreign metallic objects, such as pipelines and cables, where physical locations allow permanency of the test station and the foreign operator allows the insulation on the foreign facility to be made.

-At high voltage power transmission lines at the point where the power line crossed the pipeline, or, in the case of a parallel power line, at the points on the pipeline where the power line becomes and ceases to be parallel to the pipeline. When practical and the power line towers are metallic, the test station will be physically located near a tower.

-At insulating flanges or other insulating devices installed in the piping to isolate pipeline segments if the insulating device is not above grade.

-At galvanic anode locations where practical, except for hot spot protection, to enable testing both potential level and current output of anode (s).


The pipeline is to be hydrostatically tested in place after construction to a minimum pressure of 1.25 x MAOP (1,700 psig for 6 and 10) or 2,125 psig and 2,375 psig (1,900 psig for 8); and a maximum pressure that will produce a hoop stress equal to 110 % SMYS.

During the design phase preliminary hydrostatic test sections will be plotted on the profile sheets to determinate if pipe yielding will occur during test elevation differential.

Consideration will be given to installing short sections of heavy wall pipe in low and other critical areas to prevent pipe yielding and/or to reduce the numbers of test sections.

If the test sections are modified, they shall be submitted to INTEC Engineering for review and approval.

4 Calculation Results

4.1 Location Classes and Design Factors F

Initially the entire line is classified as Location Class 1 with a design factor 0.72. The house count and Location Classes are summarized in Table 1.

The House Count performed along with the survey confirmed the Location Class 1 classification for most of the line.

The pipe for Location Class 1 will be:

8.625O.D.6.625O.D.10.750O.D.

W.T. Grade

0.375 X600.280 X600.365 X60

0.500 X600.344 X600.500 X60.

4.2 Line Lengths

The total line length is 135 km., of which 30.2 Km are 8 O.D. Gathering System; 54 Km are 6 O.D. Exportation Liquid System, and 51 Km are 10 O.D. Exportation Gas System pipelines.

4.3 Line Sizing

The results of the hydraulic calculations for the 6; 8 and 10 O.D. pipelines and MAOP, where received from MAXUS Bolivia in Tender Document and where calculated during the feed study.

Exhibit 2 shows the Pipeline Surveyed Route, and the Exhibit 3 shows the Pipeline Schematic.

4.4 Wall thickness

4.4.1 Line Pipe

Table 4 summarizes the MAWP of the pipe to be used for the different design factors in order to achieve the MAOP of 1,700 psig. for 6 & 10, and 1,900 psig for 8.

4.4.2 Road and Railroad Crossing Pipe

Calculations were made to determinate the minimum wall thickness required to handle the combined stresses for uncased road crossings. Calculations were based on a minimum cover depth of two meters.

A comparison of the minimum required wall thickness with the proposed wall thickness is given in Table 5.

The calculations indicate that the proposed thickness are adequate in all cases.


In detail design description in Project Execution Plan

The pipe proposed for the major river crossings is with:

8.625O.D. x 0.500 W.T. API 5L-Gr.X60 ERW. (Gathering Line)

6.625O.D. x 0.344 W.T. API 5L-Gr.X60 ERW. (Exportation Line)

10.750O.D. x 0.500 W.T. API 5L-Gr.X60 ERW. (Exportation Line)

This pipe provides an actual design factor of 0.40.

4.4.4 Calculated Charpy Valves

In detail design description in Project Execution Plan

4.5 Weld Bevels

Weld bevels shall comply with Exhibit 6.

4.6 Blowdown Sizing

The blowdown time hole line of 30.2 Km. Section using six-inch blowdown stacks was calculated to be 83.5 hours.

4.7 Main Valve Settings

Table 6 shows the location of the main line valves. Valve operators will be installed at all main valves close to major river crossing. All other valves will be equipped with worm gears.

4.8 Scraper Traps

Table 7 shows the location of the scrapers traps. All scraper traps will be designed to handle an electronic inspection device (intelligent pig).

4.9 River Crossing Design

4.9.4 Major River Crossings

There are major rivers crossings are:

Pilcomayo River (Gathering Line) - Crosses on existing Bridge

Palos Blancos River (Exportation Line)

Isiri River (Exportation Line)

Monos River (Exportation Line)

The crossing of the major rivers will be designed utilizing :

-8.625O.D. x 0.500 W.T. API 5L-Gr.X60 ERW. (Gathering Line)

-6.625O.D. x 0.344 W.T. API 5L-Gr.X60 ERW. (Exportation Line)

-10.750O.D. x 0.500 W.T. API 5L-Gr.X60 ERW. (Exportation Line)

Wall thickness calculations for major river crossings will be based a Design Factor of 0.60. The pipe is to be manufactured by the ERW process. Calculations will be based on river water with a specific gravity of 1.25.

Wall thickness calculations for minor river crossing will be based on a Design Factor of 0.72. The pipe is to be manufactured by the ERW process. Calculations will be based on river water with a specific gravity of 1.25.

Special construction pipe provided with a continuous concrete coating will be used on the minor river crossing.

The pipe will be installed at a minimum depth of 10 ft. (3 meters) from the lowest point of the river bed. These crossings will be open cut.

Pilcomayo River

Gathering Line will crosses on the existing bridge.

Palos Blancos River

Exportation Line will installed at a minimum depth of 10 ft. (3 meters) from the lowest point of the river bed. These crossings will be open cut. Exact location of the crossing will be show in the Typical Major River Crossing Exhibit.

Isiri River


Los Monos River


4.9.5 Minor River Crossings

Crossing of minor rivers will be as show on Exhibit 8 utilizing 0.500 wall thickness - API 5L-X60 pipe.

Negative buoyancy will be provided by the use of continuous concrete coating. The concrete coating should have a minimum thickness of 1.5 inches and with a minimum specific weight concrete of 2.240 Kg/m.

Minor rivers will be installed with double sag bends with a minimum cover of four meters. The sag bends will have a setback of three meters minimum from the lower edge of the river bank.

4.9.6 Creek Crossings

Creek crossings will installed as shows on Exhibit 9 with single stress free sag bends with a minimum cover depth of two meters.

4.10 Wetland Areas

Line pipe coated with continuous concrete coating, one-and-a-half inches thick, with a minimum specific weight concrete of 2.240 Kg/m. Per cubic meter will be installed on wetlands. The minimum cover depth for wetlands areas is 1.50 meters from the top the concrete coating.

Pipeline Buoyancy Negative Calculation details are included in the Appendix # 5 (Design Data & Calculations), also as show on Exhibit 4b.

4.11 Meter Station

Gas Meter is Multi-Path Ultrasonic and Liquid Turbine Meter will be installed at terminal of each pipelines. The metering station will be designed including ultrasonic meter runs sized to measure the volumes and pressures. And their proving facilities shall be design and installed in accordance with the API Manual of Petroleum Measurement Standards. Also shall comply with AGA Report No. 9 Measurement of Gas by Ultrasonic Meters.

Pressure and temperature transmitters will be installed in order to communicate the flow conditions to a flow computer.

4.12 Pressure Alert Valve (PAV)

Pressure Alert Valve (PAV) will be sized and installed at terminal of each pipeline to protect plant from overpressure. Each PAV will have a monitoring valve, which will be set at a difference range than the PAV and will operate only when PAV fails to alert the pressure to meet delivery requirements.

4.13 SCADA System

The flow computers at the meter stations will be linked to the SCADA system. All the meter runs will be monitored from the central control room located in Santa Cruz. Where no telephone, radio or cellular communication is available at the meter station sites, a V-SAT unit will be installed.

4.14 Cathodic Protection System

Rectifiers will be installed throughout the pipeline. One rectifier will be installed at the beginning of the each pipelines, and one at the terminus of those pipelines.

Rectifiers with solar panels and batteries will be installed at all locations where power is not available. Test leads will be installed every two kilometers.


The pipeline will be hydrostatically tested to a minimum pressure of 1.25 x MAOP (1,700 psig for 6 & 10) or 2,125 psig and 2,375 psig (1,900 psig for 8); and a maximum pressure the lesser of 0.2 % deviation on a P-V plot. A pressure that will produce a hoop stress equal to 110 % SMYS.

The minimum hold period will be four (4) hours.

Table 1

House Count and Location Classes Summary

LOCATIONSectionLocation ClassDesign Factor FPIPEMAOPLines

FromToO.D.W.T.API 5LMAWP

KPKPinchesInchesgradepsigpsig

030G10,7280,375 / 0,500X-604050 / 54003757 / 5009Gathering

054E.10,7260,280 / 0,344X-604032 / 49543652 / 4486Export. Liq

051E.10,72100,365 / 0,500X-603154 / 43202934 / 4019Export. Gas

Table 2

Line Lengths

Section O.D.Suveyed lengthAs-builts Length

Incheskmkm

Gathering Line830

Exportation Liquid Line654

Exportation Gas Line1051

TOTAL135

Table 3

Hydraulic Calculation Results ( Example Only, Attached)

6 Liquid Pipeline Hydrostatic Test Profile, Section III.

PERFIL HIDRAULICO OLEODUCTO 6", TRAMO III

Dimetro:6 5/8"Altura Min.:423m( 602psig )

Espesor:0,280"Altura Max.:1.283m( 1.824psig )

Especificacin:API-5LX60Dif. Altura:860m( 1.223psig )

Longitud:20.000 mPresin Min.:2.125psig( 1.494m )

PMO:1.700 psig.Presin Max.:4.080psig( 2.869m )

Fecha : 31/10/02

PuntosKPAltura (m)PresinPresiones Optimizadas

(m)(psig)(m)(psig)

100+000597,6582.2723.2302.2223.159

200+400687,0982.1823.1032.1323.032

300+680598,0762.2713.2302.2213.159

400+800663,0172.2063.1372.1563.066

501+760525,0002.3443.3332.2943.263

601+950597,8202.2713.2302.2223.159

702+620500,7552.3683.3682.3193.297

803+100587,5272.2823.2452.2323.174

903+260538,0422.3313.3152.2813.244

1003+420558,9392.3103.2852.2603.214

1103+500536,0702.3333.3182.2833.247

1203+760652,2932.2173.1522.1673.082

1303+920570,0002.2993.2692.2493.199

1406+0781.283,0001.5862.2561.5362.185

1506+2831.265,0001.6042.2811.5542.210

1606+9451.249,0001.6202.3041.5702.233

1707+6001.198,0001.6712.3761.6212.306

1808+5701.234,0001.6352.3251.5852.254

1909+6191.261,0001.6082.2871.5582.216

2014+8951.096,0001.7732.5211.7232.451

2119+855800,0002.0692.9422.0192.872

2217+000720,6212.1493.0552.0992.984

2317+700690,0962.1793.0992.1293.028

2418+000566,8112.3023.2742.2533.203

2519+000462,0992.4073.4232.3573.352

2620+000423,2212.4463.4782.3963.407

Table 4

Pipe MAWP vs. MAOP

PipeMAWP psigMAOP psig

F = 0.72F = 0.72

8.625" O.D. x 0.375" W.T., API 5L - Gr.X604.0503.757

8.625" O.D. x 0.500" W.T., API 5L - Gr.X605.4005.009

6.625" O.D. x 0.280" W.T., API 5L - Gr.X604.0323.652

6.625" O.D. x 0.344" W.T., API 5L - Gr.X604.9544.486

10.750" O.D. x 0.365" W.T., API 5L - Gr.X603.1542.934

10.750" O.D. x 0.500" W.T., API 5L - Gr.X604.3204.019

Table 5

Roads and Railroad Crossing Pipe

SectionCrossingProposed

O.D. InchesW.T. InchesAPI 5L gradeProcess type

Gathering LinePublic Road8.6250.375X-60ERW

Private Road8.6250.375X-60ERW

Railroad8.6250.500X-60ERW

Exportation LinesPublic Road6.625 / 10.7500.280 / 0.365X-60ERW

Private Road6.625 / 10.7500.280 / 0.365X-60ERW

Railroad6.625 / 10.7500.280 / 0.500X-60ERW

Table 6

Mainline Valve Settings

MLV No.LineUseLocation ValveOperator

18"Wellhead Tie inX-1BallGear

2X-3

3HeaderBy Pass

4By Pass

5Plant

6MLVMLV

7MLV

8MLV

9MLV

10HeaderX-1Check

11HeaderX-3

16"MLVPlantBallGear

2MLV

3MLV

4MLV

5Hot Tap

110"MLVPlantBallGear

2MLV

3Hot Tap

Table 7

Scraper Traps Location

Location Km. PostTypeSection Line

000Launching 8Gathering

030Receiving 8 Gathering

000Launching 6Exportation

000Launching 10Exportation

051Receiving 6Exportation

054Receiving 10 Exportation

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DBM_Margarita Pipeline Rev # 2 FINAL June 30th

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