"Optimization" or "Fit for Future" is the new norm for any industry in this competitive global environment. To encounter the challenges and to embed 100% HSE, efficiency, performance and profitability in operation, maintenance and new constructions, there is an urgent necessity to review and update existing design and construction specifications related to Pipeline. Hence, this paper summarizes the latest specification optimization efforts in pipelines material engineering without compromising the safety and integrity of the assets. In ADNOC Gas Processing, specifications for various engineering disciplines namely, process, automation, control, electrical, static/ rotating equipment, piping/ pipeline, civil/ structural are followed in engineering, construction and maintenance activities. These were developed over years to steer the Company towards unparalleled reliability, operability and integrity. Now, the challenging market demands adaptability, agility and forward thinking with a need to "balance the performance with efficiency and profitability", without compromising HSE. Hence, a "Lean" approach towards the specifications is emphasized by focusing on cost-saving and value addition in terms of optimized schedules and enhanced efficiency. A set of pipelines DGSs were reviewed internally based on International standards/specifications, best engineering practices, lessons learnt from involvement with Operation and Projects and consultants optimized specifications. Through this paper, major changes in pipeline specifications are elaborated highlighting potential areas of optimization and realized cost savings. ADNOC Gas Processing (AGP) plays a strategic role in ADNOC and the UAE hydrocarbon value chain by contributing significantly for the development of the Emirates. ADNOC Gas Processing (AGP) operates and manages an integrated Pipeline Network of approximately 3500km length of Pipelines with the mission of uninterrupted supply to its Customers and any impact on the upstream plants. Various fluids are transported via pipelines such as Sales gas, Crude oil, NGL, Condensate, Water, Nitrogen and associated gases wherein majority of network contains Sales Gas. AGP is involved in executing many Major Pipeline Projects. This paper presents "Fit for Future" initiative that has changed the organizational culture and reflects effectively in all activities across the Company. As all the technical activities are based on DGSs, update plan and potential cost realization are the main drivers for enhancing the performance without compromising HSE. This approach of re-visiting the technical specifications in the light of "high efficiency with low cost" can be adopted across other OPCOs and move towards common specifications for ADNOC.
Piping systems having service temperatures lower than ambient present a challenge for the pipe support design. Pipe supports for these cold piping systems are different from normal type of supports on pipes with service temperatures above ambient. Normally hot insulated piping systems have shoe type of supports directly welded to the pipe. In this case there is no relative movement between pipe support i.e. shoe and pipe while the pipe displaces due to changes in fluid service temperature inside the pipe. As the pipe expands when temperatures rise inside pipe, it displaces from its mean position of structural support. The shoe having been welded to pipe moves along with the pipe. On the other hand, shoe type supports on cold service pipes are not directly and permanently connected to pipe. This is due to the fact that the pipe insulation on cold service piping is designed to be seal tight so that outside air cannot get inside the insulation and reach pipe surface where it starts condensation. The condensation in turn causes corrosion issues. To avoid this moist air ingress inside the insulation, the shoes are made of clamp types and are placed outside the insulation cladding. This causes problem of clamp type shoe slippage on cladding and total displacement of pipe shoe from its structural support. This paper presents an engineering study of a piping system with cold fluid service (propane) where multiple supports had fallen from the structural supports or had dislocated considerably. At few support locations, cladding was found to be damaged and ice formation was noticed. In addition, many clamped shoes had rotated as shown in figure 1. The solution as outcome of study was simple, economical and easy to implement. A comprehensive study was conducted to identify the root cause of piping supports dislocation, displacement and rotation. The static/dynamic stress analysis of the piping system was carried out. The results revealed that the displacements in the piping system were not so high to cause the supports dislocation or high displacements of shoes. In addition, the stresses on the piping system due to the contraction of pipe upon cooling were within allowable limits. Figure 1Rotated and dislocated Clamp support on Cold Service Pipes As a part of study process, operation was enquired if any upset had happened which might have caused the dislocation and abnormal movement of pipe and hence transferred to its supports. Operations informed that there was no such incident and the line had been operating normally without any trouble. The process study including review of hydraulics, verification of line size and surge was performed to identify the root cause of piping abnormal movement. The process study concluded that line size was adequate and no surge scenario was identified for the line's concerned portion. So following reasons which could cause abnormal pipe movements and dislocation of supports were ruled out based on above study: Operation upset in the piping system (such as sudden opening or closing of a valve or sudden starting/stopping of a pump),Line sizing or surge flow,Contraction of line due to cooling of piping system or piping configuration. The next step in the study was to review the support configuration in detail. Study found basic design problem with the support configuration that was the cause of supports dislocation, excessive movement and rotation of clamped supports.
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