Barracuda and Caratinga Crude Oil Fields Production

BARRACUDA AND CARATINGA CRUDE OIL FIELDS PRODUCTION FACILITIES PROJECT

Document Title

PIPING STRESS ANALYSIS PHILOSOPHY

Project Document Number

I-PH-FGG-GENL-PI-T.08-001

Owner Document Number

I-MD-3010.00-1223-200-IES-001

Field G

B03

14-Sep-01

B02

20-July-01

B01

30-May-01

A01

24-Apr-01

001

26-Mar-01

Rev

Date

Unit F

Copy Code XX

Released for Design / Revised where shaded Released for Design /Revised where shaded Released for Design /Revised where shaded- ADP 0426/01 For Comment/Revised where shaded INTER-DISCIPLINE CHECK Description

CS Approval N

Owner Approval Y

Lifecycle Code FL

DAM

MH

NLCO

RAC

JG

DAM

MH

NLCO

RAC

JG

DAM

NLCO

NLCO

RAC

JG

MH

NLCO

NLCO

RAC

JG

MH

NLCO

NLCO

RAC

JG

Originator

Checked

Discipline Lead

Mgmt

KBR

Owner

Released* *Printed initials in the approval boxes confirm that the document has been released. The originals are held within Document Management.

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CONTENTS SHEETS 1.0

INTRODUCTION

4

1.1

Purpose

4

1.2

Scope

4

2.0

CODES, STANDARDS AND REGULATIONS

4

2.1

International Codes

4

2.2

Petrobrás Codes

5

2.3

Project Documentations

5

3.0

TECHNICAL REQUIREMENTS

5

3.1

Critical Line Selection Criteria

5

3.2

Stress Calculation Methods

6

3.3

Fatigue Considerations

6

3.4

Structural Deflections

7

3.5

Inertial Accelerations

7

3.6

Wind and Wave Loads

7

3.7

Transportation

8

3.8

Blast Loading Analysis

8

3.9

Slug Flow

8

3.10 PSV Valve Piping Systems

8

3.11

Flange Leakage Check

9

4.0

STRESS ANALYSIS PROCEDURE

9

4.1

General Informations

9

4.2

Piping Stress Analysis Report

11

4.3

Load Combinations

11

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5.0

PIPING SUPPORT

12

5.1

Calculation of Span Between Supports

12

5.2

Calculation of Loads on Supports

14

6.0

EQUIPMENT NOZZLE LOADING

15

7.0

PLASTIC PIPE DESIGN

15

Appendix 1 -

Maximum Span Between Pipe Supports

Appendix 2 -

Allowable Nozzle Loads for Pressure Vessels, Columns, Shell & Tube Heat Exchangers and Equipment Packages Tie-ins

Appendix 3 -

API Equipment - Allowable Nozzle Loads

Appendix 4 -

Procedure for Stress Analysis of Piping Systems on FPSO, using Caesar II Program.

Appendix 5 -

Procedure for Stress Analysis of Glass Reinforced Vinyl Ester and Epoxy Piping (FRP) on FPSO, using Caesar II Program.

Appendix 6 -

Procedure for Blast Analysis of Piping Systems on FPSO, using Caesar II Program.

Appendix 7 -

Blast Design Criteria

Appendix 8 -

Simplified Methodology for Fatigue Analysis

Appendix 9 -

Expansion Joints Dimensional Drawing.

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1.0INTRODUCTION 1.1

Purpose

1.1.1 The purpose of this document is to define the Piping Stress Analysis Philosophy of the Floating, Production, Storage and Offloading FPSO Unit P-43 at Barracuda Field and FPSO Unit P-48 at Caratinga Field. 1.2Scope 1.2.1 It consists of balancing efforts and tensions in a system through the location of supports, guides, transverse guides and anchorages, so that satisfies acceptable conditions for the Code ASME B31.3. 1.2.2 This Philosophy is prepared to assist Piping Stress Engineers working on the project and packaged equipment Suppliers in carrying out the task of piping stress analysis in accordance with the guidelines and procedures presented here, it is intended to achieve the following objectives: •

To assure that all piping stress analysis and piping support design calculations comply with Piping Engineering Standard and Piping Specification, and all applicable regulatory codes referenced within.

•

To assure that all calculations are performed in accordance with uniform analysis procedures and methods.

•

To establish that the stress analysis problems are properly reviewed for code and specification compliance.

1.2.3 • • • • • • •

The following piping calculations are included in this document:

Stress analysis Span between supports Loads on supports Equipment nozzle loading Fatigue Analysis Blast Analysis Plastic Pipe Analysis

2.0

CODES, STANDARDS AND REGULATIONS 2.1International Codes

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•

American Society of Mechanical Engineers (ASME) ASME Pipe flanges and flanged fittings; B16.5 ASME Large Diameter Steel Flanges (NPS 26” through NPS 60”); B16.47 ASME Process piping; B31.3 ASME Section VIII Pressure vessels.

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•

American Petroleum Institute (API) API RP Recommended Practices for Design and Installation of Offshore 14E Production Platform Piping System; API Bulletin on Capabilities of API Flanges Under Combinations of STD Loads; 6AF API STD 610 Centrifugal pumps for petroleum, heavy duty chemical and gas Industry services; API STD 616 Gas Turbine; API STD 617 Centrifugal compressors for petroleum, chemical and gas industry services.

•

Welding and Research Council (WRC) WRC-107 Local stresses in spherical and cylindrical shells due to external loading.

• DNV Note no.30.2 ABS •

Classifications Notes Fatigue strength analysis for mobile offshore units. ABS Rules for Building and Classing Steel Vessels 2000.

Standard of Expansion Joint Manufacturers Association ( EJMA )

2.2PETROBRAS Codes •

N-1673 – Piping mechanical calculation criteria.

2.3 • •

Project Documentations I-ET-3010.00-1223-200-IES-001- Piping Specification mechanical calculation criteria. I-DE-3010.00-1223-293-IES-001- Piping Standard Support Drawing.

3.0

TECHNICAL REQUIREMENTS

3.1Critical Line Selection Criteria 3.1.1 Critical lines are defined as lines that require a stress analysis. They shall be selected in accordance with following selection criteria: • • • • • • -

ND 4 in and smaller with design temperature over 260 ºC (500 ºF) ND 6 in and larger with design temperature over 204 ºC (400 ºF) and less than -73 ºC (-100 ºF) ND 16 in and larger Lines having substantial concentrated loads such as valves, fittings, vertical piping. ND 3 in and larger closed pressure relief system piping, where design temperature exceeds 93 ºC (200 ºF) or is less than -73 ºC (-100 ºF) ND 3 in and larger connected to: Rotating equipment such as pumps and compressors.

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Piping to reciprocating pumps and compressors. Plate and frame heat exchanger piping. Gas turbine piping.

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• • • • • • • • • • • • • • • •

Blowdown and flare header or vent piping. Piping with pressure surge, slug and two phase flow. Normally dry firewater piping and normally charged firewater ring main piping. Piping subject to short term variations such as steam out or purge piping. Piping between riser support and pig receiver and launcher. Relief valve piping reaction forces. Lines effected by deck deflection, platform settlement, wellhead movement or any other significant displacement. Lines subjected to vacuum conditions. Lines, which may create large forces or moments on structures or skid, base. Unbalanced piping configuration, such as a long run of pipe with a short branch connected to anchor. Piping subjected to high cyclic temperature conditions. All piping with t > D/6 or P/SE > 0.385. ND 4 in & larger with t > 10% OD. FRP ND 12 in and larger. Lines with special design requirements. In addition, the piping effects of other conditions such as temperature gradients that could cause thermal bowing or where piping is connected to equipment with significant thermal growth may cause a piping engineer to analyse a line. 3.2Stress Calculation Methods

3.2.1 In general, formal computer analysis shall be performed for critical lines. However, after having reviewed a particular piping layout, the Piping Stress Engineer may apply engineering judgements and past experiences to qualify that piping system by simple calculations using nomograph charts or by visual inspection method. Even when formal computer analysis is not required, a report with all approved lines or systems shall be issued. 3.2.2

For formal computer analysis method the software Caesar II, version 4.2, must be used.

3.2.3 The axis orientation for modelling Caesar II are: “X” axis is longitudinal to ship, positive forward, “Y” axis is vertical, positive to up and “Z” axis is transverse, according to right hand rule. 3.3Fatigue Considerations 3.3.1 The FPSO vessel will be exposed to constant environment loads. These conditions will cause inertial accelerations and deflections to both the hull and topsides structures. Piping systems have to adequately withstand such loads throughout the design life. Sufficient piping flexibility must be designed so that equipment loading and pipe stresses are maintained at acceptable levels. The Weibull parameter given by the structural department based on DNV Classification Notes No 30.7 is 1,10. Fatigue of piping will be based on the S-N fatigue approach under the assumption of linear cumulative damage (Palmgrens-Miner rule from DNV Classification Notes 30.7 paragraph 1.4. P-43 BARRACUDA & P-48 CARATINGA

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3.3.2 Detail instruction for modelling fatigue in combination with other significant load combinations is given in Appendix 4, follow the orientation of DNV Classification Note N.30.2, August 1984. 3.4Structural Deflections 3.4.1 Structural deflections shall be considered for both maximum displacement stress range criteria and fatigue criteria. 3.4.2

Structural deflections will be given by Structural group. 3.5Inertial Accelerations

3.5.1 Inertial accelerations due to ship motions shall be considered for both maximum sustained stress criteria and fatigue criteria. 3.5.2

Inertial accelerations will be given by Structural group. 3.6Wind and Wave Loads

3.6.1 Wind load shall be considered in static analysis (occasional loads). Caesar II Wind Load spreadsheet will be used to calculated wind load, once for “X” direction winds and once for “Z” direction winds. The analyst is responsible to determine which direction results in the more conservative design. In general, wind speed of 40.03 m/s with 1 minute at 37m elevation shall be considered. This value is considered the most critical condition (storm). Use pipe shape factor of 0.70. 3.6.2 Effects of wave loads on riser pipes or piping inside the cargo tanks, wherever applicable, shall be considered in stress calculation. Caesar II Wave Load spreadsheet will be used to calculate wave loads. “Green Water Wave” shall be considered as follows: For all items located below an elevation of 2 meter above the Main Deck, a hydrostatic head of 2 meter and a wave velocity of 9 meter/sec horizontally in any direction shall be applied. Equipment attached to the Main Deck of the vessel shall be considered for uplift due to the buoyancy load. The green water loading shall only be considered for the 100 year centenary condition. Allowable yield stress shall be as considered for the 100 year environmental cases. Green water loading shall be considered as an additional environmental load with no increase in yield. Green Water Evaluation is described in Document I-RL-DGG-GENL-PM-BRY-004. The following are loads to be applied to various diameters.

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3.7Transportation 3.7.1 Transportation shall be considered in piping stress analysis by applying applicable accelerations given by the Preliminary Design Methodology, for pipes ND 6” and larger. 3.7.2 For FPSO, shall be considered per Specification I-ET-FGT-GENL-ST-C.06-001 TOPSIDES STRUCTURAL DESIGN PREMISSE. 3.7.3 Pipe support configuration shall be arranged and designed for both operation and transportation so that temporary supports for transportation can be kept to minimum. Temporary support for transportation shall be clearly annotated on fabrication isometrics and shall be removed after transportation. 3.8

Blast Loading Analysis

Piping systems required to hold integrity during a blast occurrence will be identified by the Safety / Loss Control Group. Those piping systems will be then designed and arranged accordingly. Blast load on piping systems will be modelled as a “drag force” proportional to the density of the vapour cloud ignited, velocity of the shock front during ignition and the projected area / drag coefficient of the piping system. For design criteria, see I-ET-FGT-GENL-ST-BRY103.-Blast Design Criteria for Vendor Equipment and Piping. Definition of systems to be analysed is found in Appendix 7-Blast Design Criteria 3.9 Slug Flow Piping systems subjected to slugging will be identified by Process group. Slug force shall be applied at changes of direction to determine stress and pipe support loads. 3.10

PSV Valve Piping Systems

PSV force will be calculated as per API 520 or taken from Relief Valve Thrust Loads, provided by Instrumentation group, times 2.0 Dynamic Load Factor (DLF). This force shall be applied at PSV valve to obtain the stress and pipe support loads.

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3.11

Flange Leakage Check

Flanges shall be located at locations that are subjected to the least external bending moments possible. The following criteria shall be used to check for flange leakage. For API flanges, external combined bending moment and axial force shall be compared and kept within the allowable given by API 6AF; For ASME B16.5 & B16.47 flanges, where the sustained stress do not exceed 0.25 x Sh and the displacement stress do not exceed 0.20 x SA, no further checks will be required. Otherwise, Caesar II flange leakage analysis shall be used. The analysis is based on ASME Section VIII Div. 1 and Div. 2, with Section VIII Appendix 2 flange rigidity. All allowable stress multipliers are 1.0. The flange is considered not to leak if the flange stresses are within allowable sustained load for the flange material and the rigidity factor is less than 1. 4.0 STRESS ANALYSIS PROCEDURE 4.1General Informations 4.1.1 The flexibility analysis due to the thermal expansions (or contractions) to the motion of the extreme piping points or to the combination of such effects, shall be made as required by ASME B31.3. This study can be made through general analytical method or graphical methods. 4.1.2 The analysis is mandatory to all critical lines that must be selection in accordance to the critical line selection criteria and a list with these lines will be prepared. This list will be used as Critical Line Index to control the progress of stress analysis activities. 4.1.3 The piping flexibility shall be obtained with an adequate non-straight lay out and the use of expansion joint shall be restricted. 4.1.4 Design temperature and design pressure shall be used in the stress analysis. Except for rotating equipment where operating temperature can be used for equipment nozzle loading qualifications. 4.1.5 Line properties, valves, material and other stress analysis input data pertaining to each problem shall be documented in the stress analysis report. 4.1.6 Valve data (weights) and special items shall be taken from one of the potential suppliers and shall be verified once the final supplier has been selected and provide the informations. It is important that the correct weight for each valve is input to the analysis of critical piping systems, such as line to / from gas compressors and pumps, and any piping system that requires spring hangers. 4.1.7 Spring hangers/supports shall be used for exceptional cases only since they may not behave consistently with inertial accelerations. Combination of snubber restraints and spring hangers/supports may have to be considered. 4.1.8 The loads and movements calculation for selection and sizing the spring supports shall be based on the general analytic method or computation method, to guarantee a better accuracy.

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4.1.9 The flexibility analysis must include the determination of all loads carried out by the piping on the fixed points (anchoring and extreme piping points), as well as on every existing motion restraints devices (longitudinal, transverse or double guides). 4.1.10 The movements imposed by equipment nozzles, on the piping system, as well as the various alternatives regarding operation start up and shutdown conditions, shall be considered on the flexibility analysis. 4.1.11 Model equipment and vessels using rigid elements of zero weight to connect nozzle node to equipment and vessel anchors. Use 1x10 E12 lbs/in stiffness for equipment anchors to the platform. 4.1.12 Use a connecting node to anchor the piping to equipment or vessel nozzles. Use modified Caesar II default stiffness for connecting node anchor stiffness to account for nozzle flexibility. 4.1.13 For rigid pipe supports, anchors and guides (to allow for steel flexibility), use stiffness factor of 1x10 E5 lbs/in. For angle iron, use stiffness factor of 50000 lbs/in, and at least, one anchor in the system shall have a restraint stiffness of 1x10E12 lbs/in. 4.1.14 Hydrostatic Test load analysis are needed for loads on supports, for all gas lines for which formal computer analysis is performed. 4.1.15 When the use of expansion joints is necessary, these shall be calculated according to EJMA standard. The designer shall obligatorily consider the loads, due to the internal pressure reaction, bellows, stiffness, direction changes and friction forces on the supports over the adjacent restraints (anchoring nozzles).

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4.2

Piping Stress Analysis Report

4.2.1 After completion of piping stress analysis using the Caesar II software, a report will be prepared with: • • • • • • • • • • • • -

Cover sheet Introduction Objective Loading Cases Design data for input Others calculations / informations for input Reference documents Conclusions Recommendations (optional) Isometric with Piping and Valve Data input and all supports Computer input print from Caesar II Computer output from Caesar II Displacement report Restraint report Stress summary Fatigue assessment 4.3Load Combinations

4.3.1 Piping systems shall be analysed for the effects of static and dynamic loadings, as applicable to each stress analysis problem. The types of loads to be considered in the analysis for each individual case shall be determined by the Piping Engineer. •

Operating Load Case

(W+P+T+D)

•

Sustained Load Case

(W+P) (Un)

•

Expansion Load Case

(T+D) (Dn)

•

Occasional and Miscell. Load Cases

- Wind Bow to Stern - Wind Port to

Starboard - Transport, with pipes empty - Wave Loads on Riser Pipes - Wave Loads on pipes in cargo tanks. - Hydrostatic Test (1.5 times design pressure at ambient temperature) - Safety Valve Reaction - Blast Loads - Slug Flow

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•

Fatigue Loading

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(See Appendix 4)

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Where, -W= Weight of pipe (and piping components), fluid and insulation -P= Internal design pressure T= Temperature gradient (based on design temperature minus min./ max. site temperature, whichever gives the maximum differential.) -D= Movement at nozzles, skid limits and anchor points -Un= Acceleration due ship motions – 3 directions -Dn= Structural Deflection due ship motions – 3 directions Stress levels shall be checked as follows: TYPE OF LOAD 1. Sustained (W+P) SL=SD+SP 2. Expansion (Thermal) SE

ASME B 31.3 REF. PARA. 302.3.5

ALLOWABLE STRESS SL