Table of Contents
Cover image
Title page
Copyright
List of Contributors
About the Authors
Preface
1. General Information
System Schematics
Cables and Ropes
How to designate and classify PE piping materials
2. Construction Right of Way
Ditching and Trenching
How engineers make pipe fit the ditch
Welding
Cross-country pipeline vertical down electrode consumption, pounds of electrode per joint
Directional Crossing
Polyethylene Piping
3. Pipe Design
Steel pipe design
How to identify the series number of flanged fittings
4. Electrical Design
Electrical design
Hazardous locations
NEMA enclosure types
Size portable electric generators
Typical wattages for tools and appliances
Knockout dimensions
National Electrical Code tables
Electrical formulas
Full-load currents–single-phase transformers
Conduit size for combinations of cables with different outside diameters
Minimum bending radius for insulated cables for permanent training during installation
Full-load currents–three-phase transformers
Motor controller sizes
Voltage drop on circuits using 600V copper conductors in steel conduit
Determine the most economical size for electric power conductors
How to find the resistance and weight of copper wires
What you should remember about electrical formulas
How to calculate microwave hops on level ground
Quick determination of hp per ampere for induction motors (3 phase) at different voltages
Chart of electric motor horsepower for pumping units
Pumping stations
Floodlighting calculations
Point-by-point method
Beam-lumen design method
Conductor size conversion chart metric to AWG
Commonly used switchgear device numbers
Bonding the grounding system to building and structure
foundations
5. Hydrostatic Testing
History of gas pipeline pressure test requirements
The benefits and limitations of hydrostatic testing
Hydrostatic testing for pipelines
Pressure testing and recordkeeping requirements – reconciling historical practices with new requirements
6. Pigging, Cleaning & Drying
A brief history of pipeline pigging
Pipeline dewatering, cleaning, and drying
Moisture content of air
Vacuum drying
Pig trap design
7. Control Valves
Control valve sizing formulas
Sizing control valves for throughput
Avoid cavitation in butterfly valves
How to read a regulator flow curve
8. Corrosion and Coatings
Types of corrosion and control methods
Fundamentals of pipeline corrosion
Estimate the pounds of sacrificial anode material required for offshore pipelines
Advances in pipeline protection
Estimate the number of squares of tape for pipe coating
Minimizing shock hazards on pipelines near HVAC lines
Pipeline external corrosion direct assessment process
9. Gas General
Know the gas laws
How to calculate the specific gravity of natural gas
Nomograph for calculating density and specific volume of gases and vapors
Facts about methane and its behavior
Conversion table for pure methane
Glossary of common gas industry terms
10. Gas Compression
Compressor definitions
Generalized compressibility factor
Nomograph aids in diagnosing compressor cylinder ills
Centrifugal compressor performance calculations
11. Gas Hydraulics
Gas pipeline hydraulics calculations
Calculate the velocity of gas in a pipeline
Nomograph for calculating Reynolds number for compressible flow friction factor for clean steel and wrought iron pipe
12. Liquids General
Determining the viscosity of crude
Calculate viscosity of a blend
Calculate specific gravity of a blend
Nomograph for calculating viscosity of slurries
Nomograph for calculating velocity of liquids in pipes
Nomograph for calculating velocity of compressible fluids in pipes
Nomograph for calculating velocity of liquids in pipes
Carbon capture and sequestration processes
CO2 pipeline infrastructure in the United States
Effect of variability on CO2 pipeline operation
13. Liquids Hydraulics
Marine hose pressure loss
Nomograph for calculating pressure drop of liquids in lines for turbulent flow
Drag-reducing agents
How to estimate the rate of liquid discharge from a pipe
14. Pumps
Centrifugal pumps
Centrifugal pump parameters and applications
How to examine centrifugal pump systems
Estimate the discharge of a centrifugal pump at various speeds
Nomograph for determining specific speed of pumps
Nomograph for determining horsepower requirement of pumps
How to select motors for field-gathering pumps
The basics of NPSH and pump operating regions
15. Measurement
Multiphase flow meter
Mass measurement light hydrocarbons
Master meter proving orifice meters in dense phase ethylene
Gas or vapor flow measurement—orifice plate flange taps
Properties of gas and vapors
Determine required orifice diameter for any required differential when the orifice and differential are known
Matching the flow meter to the application
Handling entrained gas
Proving liquid ultrasonic flow meters for custody transfer measurement
V-Cone® flow meter
Sampling and testing program for unrefined petroleum-based products
16. Instrumentation
Types of control systems
Automatic tank gauging systems and proof testing
Instrumentation and sensors for automatic tank gauging
17. Integrity Management
Overview of leak detection technologies
Inspection tools and case studies
Factors to consider when evaluating damage on pipelines
Understanding mechanical damage in pipelines
Understanding stress corrosion cracking in pipelines
When does a pipeline need revalidation?
Modeling pipeline risk assessment
A risk management tool for establishing budget priorities
Floating roof failure modes and risk
Floating roof tanks rainfall risk
18. Tanks
Classification of storage tanks
What is the difference between fixed and floating tank types?
Tank styles and appurtenances
Floating roof applications and components
Summary of federal requirements for aboveground storage tanks
Design and containment for atmospheric storage tanks
Overview of petroleum storage tank standards
Tank weight estimation tool using diameter as input variable
How to estimate flow rate from a leaking tank hole
Charts give vapor loss from internal floating-roof tanks
Estimating the contents of horizontal cylindrical tanks
Tank farm line sizing
Managing oil movement and storage in tank farms
Standard construction practices for LNG storage tanks
Choosing the best containment for LNG storage
A review of API 2350 overfill protection, 4th and 5th edition
Manual tank gauging procedures
How to apply vapor cloud analysis methodology to tank overfills
Simplified procedure to calculate emissions for liquid organic storage tanks
Calculating tank emissions with BREEZE TankESP
19. Economics
Time Value of Money
Decision and Evaluation Criteria
Sensitivity Analysis
Decision Tree Analysis
Accounting Fundamentals
20. Cost
Cost Estimation
Onshore Construction
Onshore FERC gas pipeline cost statistics in the United States, 2014–2019
How to estimate onshore pipeline construction cost using unit costs?
Offshore Construction
U.S. Gulf of Mexico pipeline cost statistics, 1995–2019
How to estimate shallow water pipeline construction cost bounds in the U.S. Gulf of Mexico using empirical data?
Offshore Decommissioning
Offshore pipeline decommissioning cost factors
How to estimate the cost to decommission shallow water pipeline in the U.S. Gulf of Mexico?
How to estimate deepwater umbilical, flowline, and riser decommissioning cost in the U.S. Gulf of Mexico?
Typical workflows for offshore pipeline decommissioning
Gas Compression Stations
Scaling Rules
Tariff Rates
How to calculate firm service with fixed maximum daily quantity and reservation charge?
How is the cost of service formula applied?
How to compute price adjustments in pipeline system quality banks
21. Health, Safety and Environment
Health
Safety
Crane and hoist safety
Tank fire types and causes
Firefighting protection systems for atmospheric storage tanks
Carbon dioxide pipeline safety and integrity
Environment
Estimating oil spill thickness on water visually
Fast discharge volume calculator for offshore leaking pipeline
Guidelines on oil characterization to inform spill planning and decision making
Oil spills inland response good practice guidelines
Calculating volatile organic compounds flash emissions from crude oil and condensate tanks at oil and gas production sites
22. Specifications
Pipeline Steel Specifications
Main differences between API 5L PSL 1 and PSL 2 pipeline
Pipeline Material Coating Specifications
Fuel Specifications
Transportation fuel specifications
Pipeline Product Specifications
23. Conversion Factors
Metric conversions metric to English, English to metric
Density conversions
General liquid density nomograph
Chart gives specific gravity/temperature relationship for petroleum oils
Weight density and specific gravity of various liquids
True vapor pressure of crude oil stocks with a Reid vapor pressure of 2–15 psi
Low temperature vapor pressures for light hydrocarbons
High temperature vapor pressures for light hydrocarbons
Hydrocarbon gas viscosity
Viscosity—equivalents of kinematic and Saybolt Universal Viscosity
Viscosity–equivalents of kinematic and Saybolt Furol Viscosity at 122 °F and 210 °F
Viscosity general conversions
ASTM standard viscosity temperature chart for liquid petroleum products
Pressure conversion chart
Energy conversion chart
Flow conversion chart
Petroleum fuels volume, weight and calorific value factors
Crude oil approximate conversion factors
Refined products approximate conversion factors
Natural gas and LNG approximate conversion factors
Units and calorific equivalents
Weight of water per cubic foot at various temperatures
Index
Copyright
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This book and the individual contributions contained in it are protected under copyright by the Publisher (other than as may be noted herein).
Notices
Knowledge and best practice in this field are constantly changing. As new research and experience broaden our understanding, changes in research methods, professional practices, or medical treatment may become necessary.
Practitioners and researchers must always rely on their own experience and knowledge in evaluating and using any information, methods, compounds, or experiments described herein. In using such information or methods they should be mindful of their own safety and the safety of others, including parties for whom they have a professional responsibility.
To the fullest extent of the law, neither the Publisher nor the authors, contributors, or editors, assume any liability for any injury and/or damage to persons or property as a ma er of products liability, negligence or otherwise, or from any use or operation of any methods, products, instructions, or ideas contained in the material herein.
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About the Authors
Mark J. Kaiser is a Professor at the Center for Energy Studies at Louisiana State University in Baton Rouge, Louisiana, where he has focused mainly on the oil, gas, and refining industry. His areas of specialization include cost evaluation, economic analysis, field development, production, and infrastructure. He has worked in the United States and internationally on numerous infrastructure and regulatory projects and started at the Center in 2001.
Edward W. McAllister has more than 50 years of experience in the pipeline industry as an Engineer, Administrator, and Project Manager. He has worked for Chevron Pipe Line Company and Gulf Pipe Line Company and has directed his own engineering services consulting firm in Houston, Texas, since 1983.
Preface
Pipeline Rules of Thumb columns began in the 1960s in Pipeline Industry Magazine, where it was conceived and wri en by Don Taylor, the first editor of the magazine. Don had been a pipeline engineer before transitioning to the publishing business, and he thought it would be helpful to provide veteran and new engineers some basic tips on various aspects of pipelining.
This was years before the pipeline technology that is available today. SCADA systems weren't in wide use at that time. Desktop computers were in someone's dreams, and engineers were still using slide rules. The Office of Pipeline Safety had not been established, and the pipeline infrastructure, especially the natural gas systems, was just starting to expand across North America.
Initially, the Rules of Thumb columns were published each month as a brief item, covering not only oil, gas, and product pipelines but also the power, water, utility, and chemical process industries. Early subjects dealt with the basics, such as how to determine the depth of cover for a new pipeline, the pressure required for a particular length and diameter line, the degrees of a pipe bend, etc.
By the late 1970s, there were sufficient tips to produce a book, and the first printing of the Pipeline Rules of Thumb Handbook (RoT) was by Gulf Publishing Company in 1978. In 1986, an advertisement for someone to update RoT was placed in Pipeline Industry Magazine. After retiring from Gulf Pipeline Company after 33 years in the pipeline business, Ed McAllister was looking for a new project and answered the ad. After interviewing with B.J. Lowe, who later formed Clarion Technical Conferences, Ed agreed to take on the task of updating the Handbook.
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The second edition of the Handbook was published in 1988 and doubled in size to about 400 pages. Subsequent editions appeared every five years or so. The third edition in 1993 was released with a software version, and the 602 page fourth edition was printed in 1998. The seventh edition was printed in 2009 by Gulf Professional Publishing, an imprint of Elsevier, and the eighth edition in 2014 came with an online companion website hosting interactive data tables.
In this ninth edition, Mark J. Kaiser, Professor at the Center for Energy Studies at Louisiana State University, joins as co-editor. After 31 years in academia and not quite ready for retirement, MJK's goal was to update RoT with the latest technical information while maintaining its basic organizational structure and layout.
Today, the pipeline industry is a multibillion-dollar global enterprise that keeps growing with new products, new methods, new technologies, and new standards to improve economics, safety, and reliability. In the future, pipelines will continue to play an important role in the efficient use and distribution of gas and liquid products, and an integral component in the transition to cleaner burning fuels, the sequestration of carbon dioxide, the transport of hydrogen, and new uses we haven't yet imagined.
The Handbook's enduring popularity and success is undoubtedly due to its focus on: (1) short practical quantitative rules of thumb, (2) clear and abundant illustrations, and (3) broad coverage of all topics related to pipelines, from A to Z. In this edition, we build upon each of these features, enhancing and expanding coverage on most major subjects, and expunging antiquated material where needed.
Four new chapters have been added on Cost, Integrity Management, Safety and Environment, and Specifications, along with a significantly expanded Tanks chapter. There is also new material on CO2 pipelines, corrosion fundamentals, hydrostatic testing, lead pipes, LNG, mechanical damage, PE piping, pigging, reading pump curves, risk management, sampling standards, proof
testing sensors, stress corrosion cracking, trench shoring, and more. RoT 9th edition checks in at a healthy and hunky 6.2 pounds 2.5 inches.
Long-time readers already know that RoT contains many different types of information in many different forms in addition to rules of thumb worked examples, design guidelines and operational tips, specification sheets, nomographs, physical properties, numerical simulations, ... Methods described range from back of envelope calculations to the results of mathematical modeling, and the wide variety of technical papers and excerpts provide detailed information to complement engineering basics.
Wri en by engineers for engineers, managers, and regulators, RoT aims to serve both working professionals and those new to the industry. We hope you agree that one of the pleasures of thumbing through the handbook is in the discovery of hidden gems wri en by the experts themselves. One cannot help feel sublime awe in the presence of such vast accumulated knowledge and experience.
Readers' comments are welcome.
Mark J. Kaiser
Baton Rouge, LA
E.W. McAllister
Houston, TX August 2022
