1: General Information, 1
Basic formulas 2
Mathematics—areas 3
Mathematics—surfaces and volumes 4
Cables and Ropes 5
Estimating strength of cable 5
Find the working strength of Manila rope 5
How large should drums and sheaves be for various types of wire rope? 5
Find advantages of block and tackle, taking into account pull out friction 6
Safe loads for wire rope 6
Stress in guy wires 7
Strength and weight of popular wire rope 9
Measuring the diameter of wire rope 9
Wire rope: ?eld troubles and their causes 9
Capacity of drums 11
Belts and Shafts 11
Determine length of a V-belt 11
Calculate stress in shaft key 12
Calculate V-belt length using simple equation 12
Estimate the horsepower that can be transmitted by a shaft 13
How to estimate length of material contained in roll 13
Convenient anti-freeze chart for winterizing cooling systems 13
How to determine glycol requirements to bring a system to a desired temperature protection level 14
Weight in pounds of round steel shafting 14
Properties of shafting 15
Tap drills and clearance drills for machine screws 16
Common nails 17
Drill sizes for pipe taps 17
Carbon steel—color and approximate temperature 17
Bolting dimensions for raised face weld neck ?anges 18
Steel ?tting dimensions 19
ANSI forged steel ?anges 20
Color codes for locating underground utilities 21
Approximate angle of repose for sloping sides of excavations 21
Trench shoring—minimum requirements 22
Reuniting separated mercury in thermometers 23
Typical wire resistance 23
How to cut odd-angle long radius elbows 24
How to read land descriptions 25
Size an air receiver for engine starting 27
Wind chill chart 28
Pipeline Pigging 29
Sizing plates 29
Caliper pigging 29
Cleaning after construction 29
Flooding for hydrotest 30
Dewatering and drying 30
Estimate volume of onshore oil spill 30
Estimating spill volume on water 32
2: Construction, 34
Project Scoping Data 35
Project scoping data worksheet for major facilities 35
Right-of-Way 36
How to determine the crop acreage included in a right-of-way strip 36
Clearing and grading right-of-way: labor/equipment considerations 36
Estimating manhours for removing trees 37
Estimating manhours for removing tree stumps 37
Clearing and grading right-of-way 38
Ditching 39
How many cubic yards of excavation in a mile of ditch? 39
Shrinkage and expansion of excavated and compacted soil 39
Ditching and trenching: labor/equipment considerations 39
Concrete Work 40
How to approximate sacks of cement needed to ?ll a form 40
What you should know about mixing and ?nishing concrete 40
Pipe Laying 40
How to determine the degrees of bend in a pipe that must ?t a ditch calling for a bend in both horizontal and vertical planes 40
How to bend pipe to ?t ditch—sags, overbends and combination bends 41
Pipe bending computations made with hand-held calculator 41
Calculate maximum bend on cold pipe 46
Determine length of a pipe bend 47
Length of pipe in arc subtended by any angle 47
Average pipelay table—Underground 48
Average pipelay table—On supports 49
Allowable pipe span between supports 49
How engineers make pipe ?t the ditch 50
Pipe Lowering 53
How to lower an existing pipeline that is still in service 53
Welding 56
When should steel be preheated before welding? 56
Welding and brazing temperatures 57
Mechanical properties of pipe welding rods 57
Lens shade selector 58
Pipeline Welding 58
How many welds will the average welder make per hour? 67
How much welding rod is required for a mile of schedule 40 pipeline? 67
How many pounds of electrodes are required per weld on line pipe? 67
Welding criteria permit safe and effective pipeline repair 68
Cross country pipeline—vertical down electrode consumption, pounds of electrode per joint 74
Guidelines for a successful directional crossing bid package 74
3: Pipe Design, 83
Steel pipe design 84
Properties of pipe 89
Length of pipe in bends 91
Calculation of pipe bends 92
Spacing of pipe supports 94
American standard taper pipe threads 96
British standard taper pipe threads 97
Normal engagement between male and female threads to make tight joints 98
Hand-held computer calculates pipe weight, contents,velocity 98
Formulas and constants of value in solving problems relating to tubular goods 101
How to calculate the contraction or expansion of a pipeline 102
Estimate weight of pipe in metric tons per kilometer 102
How to ?nd pipe weight from outside diameter and wall thickness 103
What is the maximum allowable length of unsupported line pipe? 103
Identify the schedule number of pipe by directmeasurement 103
Determine buoyancy of bare steel pipe 104
Determine buoyancy of bare and concrete coated steel pipe in water and mud 104
Weights of piping materials 105
Allowable working pressure for carbon steel pipe 105
Find the stress in pipe wall due to internal pressure 106
How to calculate stress in above/below ground transition 107
How to identify the series number of ?anged ?ttings 110
Dimensions of three-diameter ells with tangents 110
Polypipe design data 111
4: Electrical Design, 114
Electrical design 115
Hazardous locations 116
NEMA Enclosure Types 117
Size portable electric generators 118
Typical wattages for tools and applicances 119
Knockout dimensions 119
National Electrical Code Tables 120
Electrical formulas 124
Full load currents—single phase transformers 124
Full load currents—three phase transformers 125
Motor controller sizes 125
Voltage drop on circuits using 600V copper conductors in steel conduit 126
Determine the most economical size for electric power conductors 126
How to ?nd the resistance and weight of copper wires 127
What you should remember about electrical formulas 127
How to calculate microwave hops on level ground 127
For quick determination of the horsepower per ampere for induction motors (3 phase) at different voltages 128
Chart gives electric motor horsepower for pumping units 128
Pumping stations 129
Floodlighting Concepts 130
Terms 130
Floodlighting calculations 130
Point-by-point method 130
Beam-lumen method 131
Design procedure 131
Conductor size coversion chart—Metric to AWG 132
5: Hydrostatic Testing, 133
Hydrostatic testing for pipelines 134
Appendix A 140
Volume of water required to ?ll test section 140
Volume required at test pressure 141
Appendix B 142
How to use charts for estimating the amount of pressure change for a change in test water temperature 142
Compressibility factor for water 145
6: Pipeline Drying, 146
Pipeline Dewatering, Cleaning, and Drying 147
Dewatering 147
Cleaning pipelines 148
Brush pig run with gas 148
Brush pig run with liquid 148
Internal sand blasting 148
Chemical cleaning 149
Pipeline drying 149
Moisture content of air 151
Commissioning petrochemical pipelines 153
Vacuum drying 156
7: Control Valves, 159
Control valve sizing formulas 160
Sizing control valves for thruput 164
Control valve selection 169
Relief Valve Sizing, Selection, Installation and Testing 171
Rupture disc sizing 175
Rupture disc sizing using the resistance to ?ow method (KR) 176
Variable ori?ce rotary control valves 178
Sizing Valves for Gas and Vapor 180
Basic valve ?ow-capacity coef?cient (Cv) 180
8: Corrosion/Coatings, 185
Hand-held computer determines concrete coating thickness 186
NAPCA speci?cations 188
How much primer for a mile of pipe? 191
How much coal-tar enamel for a mile of pipe? 192
How much wrapping for a mile of pipe? 192
Estimating coating and wrapping materials required per mile of pipe 192
Coef?cient of friction for pipe coating materials 193
Troubleshooting cathodic protection systems: Magnesium anode system 195
Cathodic protection for pipelines 196
Estimate the pounds of sacri?cial anode material required for offshore pipelines 204
Comparison of other reference electrode potentials with that of copper-copper sulfate reference electrode at 25°C 206
Chart aids in calculating ground bed resistance and recti?er power cost 207
How can output of magnesium anodes be predicted? 208
How to determine the ef?ciency of a cathodic protection recti?er 208
How to calculate the voltage drop in ground bed cable quickly 209
What is the most economical size for a recti?er cable? 209
How to estimate the number of magnesium anodes required and their spacing for a bare line or for a corrosion “hot spot” 210
How can resistivity of fresh water be determined from chemical analysis? 210
What will be the resistance to earth of a single graphite anode? 211
How to estimate the monthly power bill for a cathodic protection recti?er 211
What will be the resistance to earth of a group of graphite anodes, in terms of the resistance of a single anode? 211
How can the current output of magnesium rod used for the cathodic protection of heat exchanger shells be predicted? 211
What spacing for test leads to measure current on a pipeline? 211
How many magnesium anodes are needed for supplementary protection to a short-circuited bare casing? 212
Group installation of sacri?cial anodes 212
How can the life of magnesium anodes be predicted? 213
How to ?nd the voltage rating of a recti?er if it is to deliver a given amount of current through a given ground bed (graphite or carbon) 213
Determining current requirements for coated lines 213
Determining current requirements for coated lines when pipe-to-soil potential values are estimated 213
HVDC effects on pipelines 214
Troubleshooting cathodic protection systems: Recti?er ground bed 218
How to control corrosion at compressor stations 219
Project leak growth 220
Advances in Pipeline Protection 221
Methods of locating coating defects 222
Case histories 225
Estimate the number of squares of tape for pipe coating (machine applied) 226
Estimate the amount of primer required for tape 227
Tape requirements for ?ttings 227
Induced AC Voltages on Pipelines May Present a Serious Hazard 228
Measuring Unwanted Alternating Current in Pipe 230
Minimizing shock hazards on pipelines near HVAC lines 235
9: Gas—General, 237
Know the gas laws 238
Calculate gas properties from a gas analysis 240
Physical properties of selected hydrocarbons and other chemicals and gases 244
Nomograph for calculating density and speci?c volume of gases and vapors 252
Considerations for Selecting Energy Measurement Equipment 253
Facts about methane and its behavior 259
Conversion table for pure methane 263
Categories of natural gas and reserves terminology 264
Glossary of common gas industry terms 265
10: Gas—Compression, 268
Compressors 269
Performance calculations for reciprocating compressors 270
Estimating suction and discharge volume bottle sizes for pulsation control for reciprocating compressors 272
Compression horsepower determination 274
Generalized compressibility factor 276
Nomograph aids in diagnosing compressor cylinder ills 277
Centrifugal Compressor Data 278
Centrifugal compressor performance calculations 278
Nomographs for estimating compressor performance 282
Estimate hp required to compress natural gas 287
Estimate compressor hp where discharge pressure is1,000psi 287
Calculate brake horsepower required to compress gas 288
How to ?nd the size fuel gas line for a compressor station 288
Estimate engine cooling water requirements 289
Estimate fuel requirements for internal combustion engines 289
Estimating fuel requirements for compressor installation 290
11: Gas—Hydraulics, 291
Gas pipeline hydraulics calculations 292
Equivalent lengths for multiple lines based on Panhandle A 293
Determine pressure loss for a low-pressure gas system 294
Nomograph for determining pipe-equivalent factors 295
How much gas is contained in a given line section? 296
How to estimate equivalent length factors for gas lines 296
Estimating comparative capacities of gas pipelines 297
Determination of leakage from gas line using pressure drop method 297
A quick way to determine size of gas gathering lines 298
Energy conversion data for estimating 298
How to estimate time required to get a shut-in test on gas transmission lines and approximate a maximum acceptable pressure loss for new lines 299
How to determine the relationship of capacity increase to investment increase 299
Estimate pipe size requirements for increasing throughput volumes of natural gas 300
Calculate line loss using cross-sectional areas table when testing mains with air or gas 301
Flow of fuel gases in pipelines 302
Calculate the velocity of gas in a pipeline 303
Determining throat pressure in a blow-down system 303
Estimate the amount of gas blown off through a line puncture 304
A practical way to calculate gas ?ow for pipelines 304
How to calculate the weight of gas in a pipeline 305
Estimate average pressure in gas pipeline using up and downstream pressures 305
Chart for determining viscosity of natural gas 306
Flow of gas 306
Multi-phase ?ow 310
Nomograph for calculating Reynolds number for compressible ?ow friction factor for clean steel and wrought iron pipe 315
12: Liquids—General, 318
Determining the viscosity of crude 319
Chart gives API gravity of blends quickly 320
Liquid gravity and density conversion chart 321
Nomograph for calculating viscosities of liquid hydrocarbons at high pressure 321
Calculate viscosity of a blend 323
Calculate gravity of a blend 323
Convert viscosity units 323
Convert speci?c gravity to API gravity 323
Calculate bulk modulus 323
Viscosities of hydrocarbon liquids 324
Nomograph for calculating viscosity of slurries 325
Nomograph for calculating velocity of liquids in pipes 327
Nomograph for calculating velocity of compressible fluids in pipes 327
Nomograph for calculating velocity of liquids in pipes 328
Derivation of basic ultrasonic ?ow equations 330
How fast does oil move in a pipeline? 332
Estimate the volume of a pipeline per linear foot using the inside diameter 332
What is the line?ll of a given pipe in barrels per mile? 332
Estimate leakage amount through small holes in a pipeline 333
Table gives velocity heads for various pipe diameters and different rates of discharge 334
13: Liquids—Hydraulics, 335
Marine Hose Data 336
CALM system 336
SALM system 336
Tandem system 337
Multi-point mooring system 337
Pressure loss in hose string 339
Pressure drop calculations for rubber hose 341
Examples of pressure drop calculations for rubber hose 341
Typical formulas used for calculating pressure drop and ?ow rates for pipelines 341
Hydraulic gradients 343
Equivalent lengths 346
Series systems 347
Looped systems 348
Calculate pressure loss in annular sections 349
Calculate pressure and temperature loss for viscous crudes =1,000 cP 349
Determine batch injection rate as per enclosure 352
Pressure Loss through Valves and Fittings 353
Representative resistance coef?cients (K) for valves and ?ttings 353
Nomograph for calculating Reynolds number for ?ow of liquids and friction factor for clean steel and wrought iron pipe 359
Nomograph for calculating pressure drop of liquids in lines for turbulent ?ow 361
Drag-Reducing Agents 365
The basics of drag reduction 365
How drag-reducing agents can outweigh looping or boosting 370
How active, passive drag affect DRA injections 376
How to estimate the rate of liquid discharge from a pipe 382
Predict subsurface temperature ranges 382
Sizing pipelines for water ?ow 383
How approximate throughput of a line can be estimated from pipe size 384
Gauge liquid ?ow where no weir or meter is available 384
Estimate crude gathering line throughput for a given pipe diameter 384
How to determine head loss due to friction in ordinary iron pipeline carrying clear water 384
How to size lines, estimate pressure drop and optimum station spacing for crude systems 385
Estimate the optimum working pressures in crude oiltransmission lines 385
How to size crude and products lines for capacity increases 386
How to determine the maximum surge pressure in liquid-?lled pipeline when a main valve is closed suddenly 386
What is the hydrostatic pressure due to a column of oil H feet in height? 386
Transient pressure analysis 387
Tank farm line sizing 396
14: Pumps, 399
Centrifugal pumps 400
Speed torque calculation 412
Pulsation Control for Reciprocating Pumps 413
Key Centrifugal Pump Parameters and How They Impact Your Applications Part 1 421
Key Centrifugal Pump Parameters and How They Impact Your Applications Part 2 426
Estimate the discharge of a centrifugal pump at various speeds 431
How to estimate the head for an average centrifugal pump 431
Find the capacity of reciprocating pump 432
How to estimate the horsepower required to pump at a given rate at a desired discharge pressure 432
Nomograph for determining reciprocating pump capacity 432
Nomograph for determining speci?c speed of pumps 434
Nomograph for determining horsepower requirement of pumps 435
How to select motors for ?eld gathering pumps 435
Reciprocating pumps 436
Understanding the basics of rotary screw pumps 445
15: Measurement, 451
Pipeline ?ow measurement—the new in?uences 452
Liquid measurement ori?ce plate ?ange taps 455
Mass measurement light hydrocarbons 459
Pipeline measurement of supercritical carbon dioxide 460
Gas Measurement 466
Master meter proving ori?ce meters in dense phase ethylene 466
Gas or vapor ?ow measurement—ori?ce plate ?ange taps 473
Properties of gas and vapors 477
Determine required ori?ce diameter for any required differential when the present ori?ce and differential are known in gas measurement 482
Estimate the temperature drop across a regulator 483
Estimate natural gas ?ow rates 483
How to estimate the average pressure differential on the remaining meter runs of a parallel system when one or more runs are shut off 484
Sizing a gas metering run 484
List of typical speci?cations for domestic and commercial natural gas 484
Determine the number of purges for sample cylinders 485
Find the British thermal units (Btu) when the speci?cgravity of a pipeline gas is known 485
Estimate for variations in measurement factors 485
Rules of measurement of gas by ori?ce meter 486
How to measure high pressure gas 486
Four ways to calculate ori?ce ?ow in ?eld 490
Practical maintenance tips for positive displacement meters 493
Sizing headers for meter stations 497
16: Instrumentation, 500
Types of control systems 501
Developments in Pipeline Instrumentation 503
Flow measurements 504
Proving devices 506
Valves 507
Acoustic line break detectors 508
“Smart” pressure sensors 509
Densitometers 510
Pipeline samplers 511
Pipeline monitoring systems 512
Computer systems 513
SCADA systems 515
Cathodic protection 515
System design guidelines 515
Future trends 516
Choosing the Right Technology for Integrated SCADA Communications 517
17: Leak Detection, 522
Pipeline Leak Detection Techniques 523
Causes and economic aspects of leaks 523
Simple leak detection systems 524
Pig-based monitoring systems 525
Computer-based monitoring systems 525
Pipeline leak phenomena 526
Background philosophy of pipeline modeling 526
Basic pipeline modeling equations 527
Impact of instrument accuracy 528
System design aspects and guidelines 529
Development of pipeline monitoring systems 530
18: Tanks, 532
Charts give vapor loss from internal ?oating-roof tanks 533
Estimating the contents of horizontal cylindrical tanks 535
How to gauge a horizontal cylindrical tank 536
Use nomograph to and tank capacity 536
Correct the volume of light fuels from actual temperature to a base of 60°F 538
Volume of liquid in vertical cylindrical tanks 538
Chart gives tank’s vapor formation rate 538
Hand-held calculator program simpli?es like computations 539
19: Maintenance, 544
How to Plan for Oil Pipeline Spills 545
Regulatory requirements 545
Contingency plan objectives 545
Related studies 545
Planning concepts 546
Contingency response 547
Immediate response 548
Immediate response actions 549
Flexible response actions 549
Training 550
20: Economics, 552
Rule of thumb speeds payroll estimates 553
Rule of thumb estimates optimum time to keep construction equipment 554
How to estimate construction costs 556
Cost estimating strategies for pipelines, stations, terminals 559
Economics 566
Time Value of Money: Concepts and Formulas 570
Simple interest vs compound interest 570
Nominal interest rate vs effective annual interest rate 571
Present value of a single cash ?ow to be received in the future 571
Future value of a single investment 572
The importance of cash ?ow diagrams 572
Analyzing and valuing investments/projects with multiple or irregular cash ?ows 572
Perpetuities 573
Future value of a periodic series of investments 574
Annuities, loans, and leases 574
Gradients (payouts/payments with constant growth rates) 575
Analyzing complex investments and cash ?ow problems 576
Decision and Evaluation Criteria for Investments and Financial Projects 577
Payback method 577
Accounting rate of return (ROR) method 578
Internal rate of return (IRR) method 579
Net present value (NPV) method 580
Sensitivity Analysis 581
Decision Tree Analysis of Investments and Financial Projects 582
Accounting Fundamentals 586
Estimate the cost of a pipeline in the US (based on 1994 data) 590
How to compare the cost of operating an engine on diesel and natural gas 591
How to estimate energy costs for different pipelinethroughputs 591
Comparing fuel costs for diesel and electric prime movers 592
Nomograph for calculating scale-up of equipment or plant costs 592
Nomograph for calculating scale-up of tank costs 594
Nomograph for determining sum-of-years depreciation 595
Nomograph for estimating interest rate of return oninvestment (“pro?tability index”) 595
Nomograph for determining break-even point 597
Chart gives unit cost per brake horsepower of reciprocating compressors with various types of prime movers 598
Chart shows in?uence on unit cost of numbers of reciprocating compressor units installed in one station 598
Chart gives unit cost per brake horsepower of centrifugal compressors with various types of prime movers 599
21: Rehabilitation—Risk
Evaluation, 600
When does a pipeline need revalidation? The in?uence of defect growth rates and inspection criteria on an operator’s maintenance program 601
Pipeline risk management 610
22: Conversion Factors, 614
Units of measurement from one system to another 615
Viscosity—equivalents of absolute viscosity 623
General liquid density nomograph 624
Chart gives speci?c gravity/temperature relationship for petroleum oils 626
Weight density and speci?c gravity of various liquids 626
Metric conversions—metric to English, English to metric 627
Temperature conversion—centigrade to Fahrenheit,Fahrenheit to centigrade 628
Viscosity—equivalents of kinematic viscosity 629
Viscosity—equivalents of kinematic and Saybolt Universal Viscosity 629
Viscosity—equivalents of kinematic and SayboltFurol Viscosity at 122°F 630
Viscosity—general conversions 631
Pressure conversion chart 633
A simple method to determine square root 633
SI data 634
Energy conversion chart 635
Flow conversion chart 635
Conversions involving different types of fuel 636
Weight of water per cubic ft at various temperatures 641
Engineering constants 641
Mensuration units 642
Minutes to decimal hours conversion table 642
How to compare costs of gas and alternate fuels 643
Typical characteristics of fuel oils 643
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