Designing and engineering a carbon dioxide pipeline

For its Eastern Shelf CO2 Pipeline project, Kinder Morgan wanted line pipe with a fine-grained steel, good toughness and ductility.

Recently, Kinder Morgan CO2 engineers were assigned the task of designing and building the 91-mile Eastern Shelf CO2 Pipeline (ESPL). The project was needed to transport CO2 to Kinder Morgan’s Katz Oil field and others in the West Texas Permian Basin for enhanced oil recovery.  The geological structure of the Permian Basin is bounded on the east by what is known as the Eastern Shelf.  The Permian Basin is one of the largest oil and natural gas structural basins in North America and encompasses over 86,000 square miles. It has been a leader in secondary and tertiary CO2 flooding operations. Today the basin produces over 350 million barrels of crude oil and 1,500 billion cubic feet of natural gas per year.

Normally any project the magnitude of the ESPL goes through several iterations in the early design phases. Engineers must work closely with business development teams and financial analysts to properly forecast as accurately as possible the immediate and future volumes necessary for economic viability. Care must also be given regarding overall operability. The design team must coordinate with immediate end users to determine delivery details; and plan for future expansion.

While the financial and operational details were being developed, the team concurrently initiated the engineering and technological details. When a consensus was reached regarding pipeline capacity, the engineering team had to be ready to begin all procurement processes for long-lead items including pipe, valves and other key components. After a hydraulics study was completed, it was concluded that the new pipeline would have a 10-in. diameter and operate at a maximum operating pressure of 2160 psi.

Project-specific pipe specifications were developed for the ESPL Project. The engineering team sought input from Kinder Morgan’s subject matter experts and industry experts outside the company. The team also referenced all applicable codes and standards. The list included: ASME, API, ASTM, NACE, ANSI, 49 CFR Part 195, as well as Kinder Morgan’s own specifications.

The specification review indicated that pipe with a fine-grained steel and desirable material properties for toughness and ductility would be required for the project. Carbon equivalency would also be another key component. The overall chemical properties for the subject pipe would include 19 chemical separate elements. The quality and quantity of each chemical element would be monitored to assure the proper “steel recipe” was developed. Sample collection methods and frequency were also determined. Development of the critical metallurgical requirements provided key insight to the engineers when they defined the quality control process.

Prior to the preparation for any request for proposals, the testing specifications were developed. These included tensile test, Charpy Impact, Hardness and hydrostatic tests. Other tests were also developed for weld seam quality, ultrasonic testing, calibration for all testing equipment, marking details and personnel certifications. Additionally, a hydrogen-induced corrosion (hic) standard was developed to assure operational flexibility.

Specifications for workmanship were also developed which addressed visual inspection guidelines, dents, offset of plate edges, weld and trim defects, bevels, arc burns, scale, pits, repair of defects, pipe mill access, notifications, markings, interior and exterior surface, transport, handling and all supporting documentation.

The unique metallurgical requirements and a dedicated schedule required Kinder Morgan’s engineering and procurement teams to seek proposals from previously approved pipe mills both domestically and abroad. Some pipe mills could not fulfill the 91-mile order on a timely basis; or they had challenges meeting the stringent metallurgical requirements. The entire process required multiple clarification meetings.

During the selection process two foreign pipe mills were identified as contenders. Through additional review and clarifications it was determined a pipe mill in Japan would serve as pipe supplier for the project. Multiple quality control meetings were conducted between Kinder Morgan and the Japanese supplier prior to the execution of all terms and conditions. It was important for each party to be aware of all expectations.

Kinder Morgan engineers required diligent quality control oversight for the project. Milestones and schedules were agreed upon in the procurement contract to insure that the engineering team would conduct onsite visits during critical phases of the milling process. A global search was also initiated to identify a pipe mill inspection firm who would oversee quality control in Japan on a daily basis. It was imperative the inspectors have all the appropriate technical and industry certifications; but also be able to communicate fluently in English and Japanese. The Kinder Morgan project engineer and procurement department interacted daily with the inspection team and pipe supplier.   

Once the pipe was milled it was temporarily stored; then transported via ship from Japan to the Port of Houston. Inspectors witnessed storage, handling and loading at the ship port in Japan. Damage could have occurred during transport if the pipe was not stored and secured properly below deck on the ship. Daily updates during transport were provided during the entire journey. Tracking the ship’s progress insured that inspectors were onsite the moment the pipe arrived at the port. The pipe was inspected in the ship’s cargo hull prior to off-loading to insure that damage did not occur during transport.

Logistics and transportation plans were developed to assure the pipe was delivered in excellent condition to pipe coaters in Houston. A coating plan was developed and inspectors witnessed the application of a protective fusion bond epoxy coating (FBE). Quality control and diligent inspection measures followed the pipe to the Eastern Shelf Pipeline jobsite.