144-111-PI-CAL-001_R1

Project No : 040176

PIPING FLEXIBILITY ANALYSIS

Client : Petro Canada

Project : De Ruyter Production Platform

Location : P11-b

Document number: 144-111-PI-CAL-001 Rev. no : R1 Page : 1 of 11


PIPING SYSTEM

SK-001

PREPARED FOR

By:Iv-Oil & Gas b.v

Rev. Description Date By Checked Appr’d by

R1 For DNV Comments / Approval 30-08-2005 G.F. Costoiu R. Tjin M. van Neck

Project No : 040176




Location : P11-b


Rev. Description Date By Checked Appr’d by

R1 For DNV Comments / Approval 30-08-2005 G.F. Costoiu R. Tjin M. van Neck

Project No : 040176




Location : P11-b


TABLE OF CONTENTS Page

1. INTRODUCTION............................................................................................................................................ 31.1 SCOPE OF WORK.............................................................................................................................. 31.2 APPLICABLE CODES......................................................................................................................... 31.3 REFERENCE DOCUMENTS..............................................................................................................3

2. SYSTEM DESIGN.......................................................................................................................................... 42.1 LINE DATA........................................................................................................................................... 42.2 CII CALCULATIONS............................................................................................................................ 42.3 DESIGN LOAD CASES........................................................................................................................ 52.4 ALLOWABLE STRESSES...................................................................................................................62.5 BLAST CALCULATIONS..................................................................................................................... 62.6 PIPE SUPPORTS................................................................................................................................ 62.7 FLANGE CONNECTIONS...................................................................................................................62.8 BRIDGE DISPLACEMENTS................................................................................................................72.9 FATIGUE CALCULATION.................................................................................................................... 7

3. STRESS ANALYSIS.................................................................................................................................... 103.1 COMPUTER MODEL......................................................................................................................... 10

4. ANALYSIS RESULTS................................................................................................................................. 114.1 STRESSES........................................................................................................................................ 114.2 FATIGUE............................................................................................................................................ 114.3 FLANGES.......................................................................................................................................... 11

APPENDICES

APPENDIX 1 STRESS SKETCHES

APPENDIX 2 PIPE SUPPORT DETAILED DRAWINGS

APPENDIX 3 CONSTRUCTION ISOMETRICS

APPENDIX 4 MISCELLANEOUS CALCULATIONSAppendix 4.1 Flange Calculations

Appendix 4.2 Relative Bridge Displacements

Appendix 4.3 Fatigue Displacements

APPENDIX 5 CAESAR II PRINTOUT

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Location : P11-b

Document number: 144-111-PI-CAL-001 Rev. no : R1 Page : 4 of 11 1. INTRODUCTION

1.1 SCOPE OF WORK

The purpose of this report is to demonstrate that piping systems SK-001, part of De Ruyter topside piping, has inherent flexibility to accommodate displacements due to design conditions, without imposing any excessive loads on pipe supports and equipment nozzles. Furthermore the piping stress level has to satisfy the designated code.

1.2 APPLICABLE CODES

The governing code for piping design is:

ASME B31.3 Process Piping

For items not covered by the above-mentioned document, reference is made to the following codes and standards:

ASME VIII Rules for construction of pressure vessels, Division 1 and 2

ASME III Rules for Construction of Nuclear Facility Components, Division 1

ASME B16.5 Pipe Flanges and Flanged Fittings

WRC-107 Local stresses in Spherical and Cylindrical Shells due to External loadings

1.3 REFERENCE DOCUMENTS

144-002-PI-SPE-0002 Piping Classes Specifications

144-002-PI-SPE-0007 Plant Department Pipe Stress Design Criteria

144-111-PI-LST-0001 Plant Department Critical Line List

144-000-PR-LST-0001 Process Line List

144-000-ME-SPE-0004 Nozzle Loads on Equipment

144-002-HE-TNS-0007 Blast Design Strategy and Overpressures

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Document number: 144-111-PI-CAL-001 Rev. no : R1 Page : 5 of 11 2. SYSTEM DESIGN

2.1 LINE DATA

Functional design data, used for analysis, is summarised below:

Item/ Line No.

Pipe

Cla

ss

Cor

rosi

on

Allo

wan

ce

Des

ign

Pres

sure

Hyd

rote

st P

ress

ure

Max

imum

Des

ign

Tem

pera

ture

Min

imum

Des

ign

Tem

pera

ture

Ope

ratin

g Te

mp.

Med

ium

Den

sity

Flan

ge R

atin

g

Drawing Number

- mm barg barg °C °C °C Kg/m3 # -

6”-HC-100-002-E41-D E41 3 165 247.5 75 -11 60 1025 1500100002-0501/

1203

6”-HC-100-004-E41-D E41 3 165 247.5 75 -11 60 1025 1500100004-0501/

1203

6”-HC-100-006-E41-D E41 3 165 247.5 75 -11 60 1025 1500100006-0501/

1203

Note: - Installation temperature assumed as -11°C throughout.

2.2 CII CALCULATIONS

The following CII calculations have been performed:

SK-001-R1 : Design conditions.

SK-001B-R1 : Blast loads.

SK-001F-R1 : Fatigue calculation.

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2.3 DESIGN LOAD CASES

The Functional Loads, used to generate the design load cases, comprise the following:

(W) Gravity load, due to self-weight of steel, contents and insulation.

(P1) Pressure load, due to design pressure.

(T1) Thermal load due to maximum design temperature.

(D1..4) Relative bridge displacements (refer to paragraph 2.8 of this report for further details).

(H) Hanger load.

(WIN1..4) Wind loads based on 42m/s velocity at 10m (100 year - 3 sec’s gust). Loads are applied in +X for Case 1, -X for Case2, +Z for Case 3 and –Z for Case 4.

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2.4 ALLOWABLE STRESSES

The allowable stresses are in compliance with the criteria specified in ASME B31.3

Material Max temp [ºC ]

Material Properties [N/ mm²] Allowable stresses [N/mm²]

SMTS SMYS Yield Sh Sa (EXP) Socc (OCC)

A333 Gr. 6 75 414 241 227.5137.9 207 183

Sustained Stress range Occasional

Note : Stress range is based on a stress reduction factor (f) of 1.

2.5 BLAST CALCULATIONS

This system is non blast critical. However blast loads are applied from node 350, down to production header in order to determine the extreme loads at supports closest to (and at) production header. Refer to system SK-009 for blast critical pipework.

Supports at the following node numbers are designed for blast loads: 350, 2350, 3350, 2380 and 3380.

Blast Load: 20 KN/m2

Shape factor: 0.9 (conservative approach resulting in approximately 20% safety margin).

Fig 2.5.1 Blast load cases Fig 2.5.2 Sample blast loads using CII wind modeler

The blast loads are generated using CII wind modeler (see figure 2.5.2). The loads are applied in four (4) directions as described in section 2.3, above. Blast load cases used for calculation are listed in figure 2.5.1. Definition of loads is as per paragraph 2.3 with exception of (WIN1…4) which represents the blast loads and T1 = operating temperature (60oC) and P1 = operating pressure (17barg).

2.6 PIPE SUPPORTS

All loads on supports are summarised in the Pipe Stress Analysis Output.

The loads include the friction forces. In this case a friction coefficient of 0.4 is taken into account for friction between steel surfaces. In special cases where PTFE-sliding pads may be applied a friction coefficient of 0.1 shall be taken into account. The pipe support detail drawings are included in Appendix 2.

2.7 FLANGE CONNECTIONS

Flange connections are modelled in CAESAR II by anchoring together the rigid elements through a CNODE. This enables an easy check of the external loads using CII restraint output summary.

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For B16.5 flange analysis, either of the following two methods has been used:

1. External loads acting on these connections are assessed using the ASME BPVC, Section VIII, Division 1, Appendix 2 in combination with Section III, subsection NC. Actual hub length is used.

2. External loads acting on these connections are assessed using the ASME Section III, Division 1, subsection NC-3658.3, ASME B16.5a Flanged Joints with High Strength Bolting, with yield stress at temperature, SY, substituted with B31.3 allowable stress, Sh.

Flange analysis is performed for maximum acting loads and calculations are performed for each flange size in the calculation.

2.8 BRIDGE DISPLACEMENTS

The relative displacements between WB (wellbay) and IPD (integrated production deck) are accounted for in the stress analysis by using Caesar’s II forced nodal displacements D1 u/I D8. These displacements are applied to the supports connected to WB while the other supports, connected to IPD, are fixed (no movements).

The movements of WB and IPD are determined by others and are provided in SQ-425, included in Appendix 4.2 of this report. Displacements for 8 wave directions and for 1 year and 100 year extreme conditions are given.

For the purpose of this report, the 100 year displacements are selected. Further more the similar locations at WB and IPD at top of leg B4, elevation +26 and +35 are selected. The relative displacements are determined by subtracting the WB movements from IPD movements. These displacements are applied at the following supports:Node 160 and 290 (line 6”-HC-100-002),Node 2160 and 2290 (line 6”-HC-100-005),Node 3160 and 3290 (line 6”-HC-100-006).

The relative displacements, calculated as indicated above, are included in the computer model using the nodal displacement sets:

D1 100 year, wave 00 deg.








Refer to Appendix 4.2 for details.

2.9 FATIGUE CALCULATION

The stress fluctuations, imposed over the design life (20 years), have been considered for the fatigue assessment. The fluctuating loads are divided into two categories:

A. Operating loads

B. Environmental loads due to wave (relative platform deflections)

The fatigue life is acceptable if the sum of usage ratios (for all considered load cases) is smaller than 1:

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Location : P11-b


Where:

n = calculated number of cyclesN = allowable number of cycles k = number of load cases

The allowable number of cycles is determined, by Caesar II, using the ASME VIII Division 2, Figure 5.110.1, UTS<80 ksi. Stress data points are entered as allowable stress range, see figure 2.9.1. Values higher than 106 cycles are extrapolated.

Operating loads (A) used for fatigue analysis are described below.

- Pressure variations assumed from atmospheric to design pressure of 165 barg. Caesar II abbreviation P1.

- Temperature variations assumed from minimum design (-11oC) to maximum design (75oC). Caesar II abbreviation T1.

- Relative displacements due to 382t of wireline equipment on IPD weather deck. Caesar II abbreviation D9.

The number of cycles for operating loads is determined assuming five a week: 5 x 52 x 20 = 5200 cycles

Environmental loads (B) used for fatigue analysis are described below.

- Relative displacements due to waves. The wave scattered diagram, derived from doc no 144-002-SG-CAL-2003, has been used to determine the number of cycles. Refer to figure 2.9.3. All waves are divided in four blocks and for each block the displacements for highest wave is determined . The stresses calculated for these displacements are considered to apply for all number of cycles found in that particular block (conservative approach).

The relative displacements are calculated by linear interpolation using the wave heights of 100 year wave (13.8m), 1 year wave (10m). Further more the wave direction resulting in highest stresses has been selected and used for all other directions. That is 45o – 225o direction. Detailed calculations are enclosed in Appendix 4.3 of this report.

CII Load Cases

Load cases generated for fatigue calculation are indicated in figure 2.9.2. Definition of loads is as per paragraph 2.3 with exception of (D1…9).

D1 relative displacements - waves in Block 1 / 45o direction.








D9 relative displacements due to 382t of wireline equipment on IPD weather deck.

Fig. 2.9.1

Fig. 2.9.2 CII load cases

Fig. 2.9.2 Caesar II fatigue load cases

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Tabl

e 2.

9.3

W

ave

scat

ter

diag

ram

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3. STRESS ANALYSIS

3.1 COMPUTER MODELFinite element computer models are developed based on the stress isometric included in Appendix 1.

Pipe stress program CAESAR II version 4.50, developed and marketed by COADE Engineering Software has been used for the analysis of the piping systems. This software package is a widely accepted tool to perform comprehensive stress analysis of complex piping systems.

The global co-ordinate system used in the computer model is indicated on the stress isometrics. Small differences in dimensions between the piping isometrics and the calculations may occur, but have no significant effect on the analysis.

Notes

This system is non blast critical. However, blast loads have been applied only to determine the loads at and near production manifold 10”-HC-120-001-E41.

The effects of platform movements have been simulated by including the relative displacements at the supports connected to WB structure. All other support, connected to IPD structure, are fixed.

System Overlap

The production manifold (nodes 1010 to 1400), part of system SK009, has been included in this calculation for overlap.

The pipe routing of this system is shown below:

Pipe supports connected to WB

310-VN-01A

Overlap – Sys. SK-009 Pipe supports connected to IPD

Limit of blast applied loads

N160N2160

N3160

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Location : P11-b

Document number: 144-111-PI-CAL-001 Rev. no : R1 Page : 12 of 11 4. ANALYSIS RESULTS

4.1 STRESSES

The maximum calculated code stresses are summarized below and compared against B31.3 code allowable values.

All stresses are found to be within the allowable limits.

Table 4.1.1 Maximum Sustained Stress (SK-001-R1)

Case No. Node MaterialCode Stress

N/mm²

Allowable Stress

N/mm²

Ratio

2 1050 A333 Gr. 6 71.2 137.9 0.51

Table 4.1.2 Maximum Stress Range (SK-001-R1)


N/mm²

Allowable Stress

N/mm²

Ratio

22 3319 A333 Gr. 6 143.6 207 0.69

Table 4.1.3 Maximum Occasional Stress – Wind effects (SK-001-R1)


N/mm²

Allowable Stress

N/mm²

Ratio

31 1050 A333 Gr. 6 72.8 183 0.40

4.2 FATIGUE

The fatigue life is found acceptable, since the maximum utilization ratio, found at node 3319, is:

0.62 < 1.

4.3 FLANGES

The integrity of the ASME B16.5 flanges, under the maximum external loads, has been checked as outlined in section 2.7. The external loads are found to be acceptable. Detailed flange calculations and the summary have been included in Appendix 4.1 where required.

Project No : 040176




Location : P11-b


Project no : 040176


Project title : De Ruyter Production Platform

Location : P11-b


Document number : 144-111-PI-CAL-001 Rev. no : R1

APPENDIX 1

STRESS SKETCHES

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Location : P11-b



APPENDIX 2

PIPE SUPPORT DETAILED DRAWINGS

Hold for node: 160; 290; 310; 330; 340; 350; 2160; 2290; 2310; 2330; 2340; 2350; 23803160; 3290; 3310; 3330; 3340; 3350; 3380

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APPENDIX 3

CONSTRUCTION ISOMETRICS

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APPENDIX 4

MISCELLANEOUS CALCULATIONS

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APPENDIX 4.1

FLANGE CALCULATIONS

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APPENDIX 4.2

RELATIVE BRIDGE DISPLACEMENTS

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APPENDIX 4.3

FATIGUE DISPLACEMENTS

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APPENDIX 5

CAESAR II PRINTOUT

Documents

144-111-PI-CAL-001_R1