CO2 Onshore-pipeline-mechanical-design-report.pdf
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Mechanical Design report for CO2 onshore pipeline construction...
Description
KCP-GNS-PLD-DRP-0004 Rev: 03 Project Title:
Kingsnorth Carbon Capture & Storage Project
Document Title:
Onshore Pipeline Mechanical Design Report
Page 1 of 31
Onshore Pipeline Mechanical Design Report Table of Contents 1 Summary ......................................................................................................................... 3 2 Introduction ...................................................................................................................... 5 2.1 Scope of Document .................................................................................................. 5 2.2 Definitions ................................................................................................................. 6 2.3 Abbreviations ............................................................................................................ 6 2.4 System of Units......................................................................................................... 6 2.5 Cross References ..................................................................................................... 6 3 Design Data ..................................................................................................................... 7 3.1 Linepipe Properties ................................................................................................... 7 3.2 Operating Data ......................................................................................................... 8 3.3 Environmental Data .................................................................................................. 8 3.4 External Corrosion Protection ................................................................................... 8 4 Mechanical Calculations .................................................................................................. 9 4.1 Wall Thickness Calculations ..................................................................................... 9 4.2 Circumferential Stresses ......................................................................................... 10 4.3 Longitudinal Stresses for Fully Restrained Pipeline................................................. 10 4.4 Equivalent Stress for Fully Restrained Pipeline ....................................................... 11 4.5 Anchor Force and Displacement, Partly Restrained Pipeline .................................. 12 4.6 Anti-buoyancy Assessment ..................................................................................... 13 4.7 Upheaval Buckling .................................................................................................. 13 4.8 API RP 1102 Road Crossing Assessment .............................................................. 14 5 Mandatory References .................................................................................................. 15 5.1 Codes and Standards ............................................................................................. 15 6 Supporting References .................................................................................................. 16 6.1 Project Documentation ............................................................................................ 16 6.2 External Documentation .......................................................................................... 16 7 Appendix A, PD 8010-1 Mechanical Design Calculations .............................................. 17 7.1 Wall Thickness........................................................................................................ 17 7.2 Expansion ............................................................................................................... 18 7.3 Upheaval Buckling .................................................................................................. 24 7.4 Specific Gravity (Bouyancy) .................................................................................... 25 8 Appendix B, API RP 1102 Uncased Road Crossing Assessment .................................. 26 9 Appendix C, DNV RP-J202 Wall Thickness Calculations ............................................... 30 9.1 Extract from Pressure Containment Calculations .................................................... 31
Kingsnorth CCS De monstration Pro ject The information contained in this document (the Infor ma tion) is provided in good faith. E.ON UK plc, its subcontractors, subsidiaries, affiliates, e mployees, advisers, and the Depart ment of Energy and Climate Chan ge (DECC) make no representation or warranty as to the accuracy, reliability or completeness of the Infor mation and neither E.ON UK plc nor any of its subcontractors, subsidiaries, affiliates, e mployees, advisers or DECC shall have any liability whatsoever fo r any direct or indirect loss howsoe ver arising from the use of the Infor mation by any party.
KCP-GNS-PLD-DRP-0004 Rev: 03 Project Title:
Kingsnorth Carbon Capture & Storage Project
Document Title:
Onshore Pipeline Mechanical Design Report
Page 2 of 31
List of Tables Table 1.0-a Table 1.0-b Table 1.0-c Table 1.0-d Table 3.1-a Table 3.2-a Table 3.3-a Table 4.1-a Table 4.2-a Table 4.2-b Table 4.3-a Table 4.3-b Table 4.4-a Table 4.4-b Table 4.5-a Table 4.5-b Table 4.6-a Table 4.7-a Table 9.0-a Table 9.0-b Table 9.0-c
Recommended Wall Thickness for Pressure Containment (ISO 3183 L450M) .........3 Recommended Wall Thickness for Pressure Containment (ISO 3183 L485M) .........3 Pipeline Anchor Forces...............................................................................................4 Concrete Coating Requirements ................................................................................4 Linepipe Properties .....................................................................................................7 Operating Data ...........................................................................................................8 Environmental Data ....................................................................................................8 Wall Thickness Results...............................................................................................9 Circumferential Stress (DF 0.72) ............................................................................. 10 Circumferential Stress (DF 0.30) ............................................................................. 10 Longitudinal Operating Stress for Fully Restrained Pipeline (DF 0.72) ................... 11 Longitudinal Operating Stress for Fully Restrained Pipeline (DF 0.30) ................... 11 Equivalent Operating Stress for Fully Restrained Pipeline (DF 0.72) ..................... 11 Equivalent Operating Stress for Fully Restrained Pipeline (DF 0.30) ..................... 12 Anchor Force, Active Length and End Displacement (DF 0.72).............................. 12 Anchor Force, Active Length and End Displacement (DF 0.30).............................. 12 Continuous Concrete Coating Thickness ................................................................ 13 Relationship between Imperfection Height and Depth of Cover ............................. 13 DNV RP-J202 Wall Thickness Requirements (120barg) ......................................... 30 DNV RP-J202 Wall Thickness Requirements (150barg, base case) ...................... 30 DNV RP-J202 Wall Thickness Requirements (200barg) ......................................... 30
Table of Figures Figure 2-1-a
Outline System Schematic..........................................................................................5
Table of Holds HOLD
Description
Section
1
Maximum allowable operating pressure
3.2
2
Maximum operating temperature
3.2
3
Soil density
3.3
Kingsnorth CCS De monstration Pro ject The information contained in this document (the Infor ma tion) is provided in good faith. E.ON UK plc, its subcontractors, subsidiaries, affiliates, e mployees, advisers, and the Depart ment of Energy and Climate Chan ge (DECC) make no representation or warranty as to the accuracy, reliability or completeness of the Infor mation and neither E.ON UK plc nor any of its subcontractors, subsidiaries, affiliates, e mployees, advisers or DECC shall have any liability whatsoever fo r any direct or indirect loss howsoe ver arising from the use of the Infor mation by any party.
KCP-GNS-PLD-DRP-0004 Rev: 03 Project Title:
Kingsnorth Carbon Capture & Storage Project
Document Title:
Onshore Pipeline Mechanical Design Report
1
Page 3 of 31
Summary This document addresses the methodology and calculations performed to determine the mechanical strength and stability of the onshore Kingsnorth CCS pipeline. Mechanical calculations based on a linepipe material grade of ISO 3183 L450M (API 5L X65 equivalent) were carried out for the onshore section of the pipeline for design pressure options of 120barg, 150barg (base case) and 200barg with a design temperature of 70degC. Comparative wall thicknesses for pressure containment only have been conducted for a material grade of ISO 3183 L485M (API 5L X70 equivalent). Results for the base case option are shown in bold. A new code which specifically addresses the transportation of CO2 has been developed and is available for general use, DNV RP-J202, Design and Operation of CO2 Pipelines [M7]. This code supplements the requirements of ISO 13623, Petroleum and Natural Gas Industries - Pipeline Transportation Systems [M8] and provides guidance on the determination of the required pipeline wall thickness as appropriate for the location class and fluid category. Neither code however, provides guidance on the determination of Building Proximity Distances (BPD) for differing design factors which is required for pipeline routing. DNV RP-J202 [M7] recommends the use of CO2 dispersion modelling, however, until such information or guidance is available, the calculations herein, as a minimum, meet the requirements of PD 8010-1, Code of Practice for Pipelines Part 1: Steel Pipelines on Land [M2]. This methodology should be reviewed during FEED. To facilitate pigging operations, the pipeline is designed with a constant inside diameter (ID) such that the onshore pipeline is matched to the offshore pipeline and the outside diameter (OD) will vary accordingly. The recommended nominal wall thicknesses for pressure containment are shown in Tables 1.0-a and 1.0-b: Description
Unit
Design Factor 0.72 (Standard Wall)
Design Factor 0.30 (Heavy Wall)
Design Pressure
barg
120.0
150.0
200.0
120.0
150.0
200.0
Outside Diameter
mm
914.0
920.4
921.6
967.4
982.2
1006.0
Inside Diameter
mm
872.8
869.6
856.8
872.8
869.6
856.8
Wall Thickness
mm
20.6
25.4
32.4
47.3
56.3
74.6
Table 1.0-a
Recommended Wall Thickness for Pressure Containment (ISO 3183 L450M)
Description
Unit
Design Pressure
barg
120.0
150.0
200.0
120.0
150.0
200.0
Outside Diameter
mm
914.0
917.2
920.2
960.4
974.2
998.2
Inside Diameter
mm
872.8
869.6
860.0
872.8
869.6
860.0
Wall Thickness
mm
20.6
23.8
30.1
43.8
52.3
69.1
Table 1.0-b
Design Factor 0.72 (Standard Wall)
Design Factor 0.30 (Heavy Wall)
Recommended Wall Thickness for Pressure Containment (ISO 3183 L485M)
The calculations for pressure containment show that for the 150barg design pressure option (base case), the use of ISO 3183 L485M (API 5L X70) will result in a wall thickness reduction of 1.5mm for a design factor of 0.72 and 4.0mm for a design factor of 0.30. Higher grade materials such as API 5L X80 and API 5L X100 could also be considered in order to reduce wall thickness however due consideration would need to be given to Kingsnorth CCS De monstration Pro ject The information contained in this document (the Infor ma tion) is provided in good faith. E.ON UK plc, its subcontractors, subsidiaries, affiliates, e mployees, advisers, and the Depart ment of Energy and Climate Chan ge (DECC) make no representation or warranty as to the accuracy, reliability or completeness of the Infor mation and neither E.ON UK plc nor any of its subcontractors, subsidiaries, affiliates, e mployees, advisers or DECC shall have any liability whatsoever fo r any direct or indirect loss howsoe ver arising from the use of the Infor mation by any party.
KCP-GNS-PLD-DRP-0004 Rev: 03 Project Title:
Kingsnorth Carbon Capture & Storage Project
Document Title:
Onshore Pipeline Mechanical Design Report
Page 4 of 31
material handling requirements during installation, weldability, pipe stability etc. The use of higher grade materials should be reviewed during FEED as part of the material selection process and cost benefit assessment. Wall thickness requirements for pressure containment in accordance with DNV RP-J202 [M7] are presented in Appendix C. For the 150barg design pressure option (base case) there would be a wall thickness reduction of 1.6mm for the equivalent “standard wall” pipe and 24.5mm for the equivalent “heavy wall” pipe over those calculated in accordance with PD 8010-1 [M2] for a ISO 3183 L450M grade material. In accordance with PD 8010-1 [M2], the proposed nominal wall thicknesses for the pipeline are sufficient to withstand the additional loads to which the pipeline will be subjected during installation and operation. The force required to fully restrain the displacement of the pipeline at the maximum operating temperature of 40degC is presented in Table 1.0-c. Consideration should also be given to the inclusion of an expansion loop to accommodate the pipeline end expansion. This shall be confirmed during detailed design when a full stress analysis is performed. Description
Unit
Design Pressure
barg
120
150
200
120
150
200
Anchor Force
kN
7,050
8,724
11,131
12,718
15,357
20,332
Active length
m
190.0
229.0
285.0
301.0
343.0
429.0
mm
55.8
67.3
84.7
67.6
78.8
96.5
End Displacement Table 1.0-c
Design Factor 0.72
Design Factor 0.30
Pipeline Anchor Forces
Buoyancy control, through the application of continuous concrete weight coating, will be required in areas of high water table, when the design factor is 0.72, because the pipeline is not heavy enough and will have a tendency to float when empty. The continuous concrete 3 weight coating thickness was determined assuming a concrete with a density of 3040kg/m 3 and a ground water density of 1025kg/m (seawater). Description
Unit
Design Pressure
barg
120.0
150.0
200.0
Required Coating Thickness
mm
50.0
33.0
25.0
Table 1.0-d Note 1:
Design Factor 0.72
Design Factor 0.30
(1)
120.0
150.0
200.0
0.0
0.0
0.0
Concrete Coating Requirements
For manufacturing purposes the minimum thickness of continuous concrete weight coating is limited to 25mm. An alternative would be to utilise intermittent set-on saddle weights.
No additional measures are needed to counter upheaval buckling. A road crossing assessment performed in accordance with the requirements of API RP 1102 [M6], shows that the proposed wall thicknesses for each pressure case with a design factor of 0.3, satisfy the stress criteria for an uncased highway installation.
Kingsnorth CCS De monstration Pro ject The information contained in this document (the Infor ma tion) is provided in good faith. E.ON UK plc, its subcontractors, subsidiaries, affiliates, e mployees, advisers, and the Depart ment of Energy and Climate Chan ge (DECC) make no representation or warranty as to the accuracy, reliability or completeness of the Infor mation and neither E.ON UK plc nor any of its subcontractors, subsidiaries, affiliates, e mployees, advisers or DECC shall have any liability whatsoever fo r any direct or indirect loss howsoe ver arising from the use of the Infor mation by any party.
KCP-GNS-PLD-DRP-0004 Rev: 03 Project Title:
Kingsnorth Carbon Capture & Storage Project
Document Title:
Onshore Pipeline Mechanical Design Report
2
Page 5 of 31
Introduction 2.1 Scope of Document This document addresses the methodology and calculations performed to determine the mechanical strength and stability of the onshore section of the Kingsnorth CCS pipeline. The calculations, as a minimum, will meet the requirements of PD 8010-1, Code of Practice for Pipelines Part 1: Steel Pipelines on Land [M2]. An outline schematic of the pipeline system is shown in Figure 2.1-a. The limits of the onshore pipeline are defined as follows: Pipeline landfall valve; Kingsnorth Power Station CCS pig launcher.
Figure 2.1-a
Outline System Schematic
The pipeline wall thickness shall be calculated for the selected material grade ISO 3183 L450M (API 5L X65 equivalent) as identified in the Basis of Design for Studies - Phase 1A [S1] based on internal design pressure. Design pressure options of 120barg, 150barg (base case) and 200barg have been considered. The pipeline has also been assessed for strength and stability under the various loading conditions expected during installation and operation, as summarised below: 1.
Circumferential stresses due to internal pressure are calculated;
2.
Longitudinal tensile / compressive stresses due to internal pressure and thermal loading were determined for the restrained condition;
3.
The Von Mises yield criterion has been used to determine the developed equivalent stress, relating the state of combined stress to the uniaxial state of stress;
4.
The anchor force for the fully restrained pipeline and displacements at the pipeline free end if it was allowed to expand, together with the anchor (active) length of pipeline have also been determined;
5.
The tendency for flotation in submerged soil conditions has been assessed;
Kingsnorth CCS De monstration Pro ject The information contained in this document (the Infor ma tion) is provided in good faith. E.ON UK plc, its subcontractors, subsidiaries, affiliates, e mployees, advisers, and the Depart ment of Energy and Climate Chan ge (DECC) make no representation or warranty as to the accuracy, reliability or completeness of the Infor mation and neither E.ON UK plc nor any of its subcontractors, subsidiaries, affiliates, e mployees, advisers or DECC shall have any liability whatsoever fo r any direct or indirect loss howsoe ver arising from the use of the Infor mation by any party.
KCP-GNS-PLD-DRP-0004 Rev: 03 Project Title:
Kingsnorth Carbon Capture & Storage Project
Document Title:
Onshore Pipeline Mechanical Design Report
Page 6 of 31
6.
The pipeline has also been assessed for propensity to upheaval buckling for several imperfection heights;
7.
At road crossings the pipeline will be installed uncased. The stresses developing in the wall of the pipeline due to vehicle loading were analysed and assessed in accordance with API RP 1102, Steel Pipeline Crossing Railroads and Highways [M6].
2.2 Definitions For the purpose of this document the following definitions shall apply: Shall
Indicates mandatory requirement
Should
Indicates preferred course of action
May
Indicates optional course of action
In the context of this document, the titles and definitions shall be specific when shown in upper case and non-specific when shown in lower case. 2.3 Abbreviations Within this document, the following abbreviations are used: 3LPE API ASME BPD CCS DF DNV FEED GOGC ID ISO MAOP OD SAWL SMYS
3 Layer Polyethylene American Petroleum Institute American Society of Mechanical Engineers Building Proximity Distance CO2 Capture and Storage Design Factor Det Norske Veritas Front End Engineering Design Genesis Oil and Gas Consultants Inside Diameter International Organisation for Standardisation Maximum Allowable Operating Pressure Outside Diameter Submerged Arc Weld Longitudinal Specified Minimum Yield Strength
2.4 System of Units Reference shall be made to the Overall Project Units, KCP-EEN-PCD-DPR-0001 [S5]. 2.5 Cross References Where cross-references to other parts of this document are made, the referenced section number is shown in brackets. Other documents referenced by this report are listed in (5) and (6). Kingsnorth CCS De monstration Pro ject The information contained in this document (the Infor ma tion) is provided in good faith. E.ON UK plc, its subcontractors, subsidiaries, affiliates, e mployees, advisers, and the Depart ment of Energy and Climate Chan ge (DECC) make no representation or warranty as to the accuracy, reliability or completeness of the Infor mation and neither E.ON UK plc nor any of its subcontractors, subsidiaries, affiliates, e mployees, advisers or DECC shall have any liability whatsoever fo r any direct or indirect loss howsoe ver arising from the use of the Infor mation by any party.
KCP-GNS-PLD-DRP-0004 Rev: 03 Project Title:
Kingsnorth Carbon Capture & Storage Project
Document Title:
Onshore Pipeline Mechanical Design Report
3
Page 7 of 31
Design Data The data presented below and used for the analysis is extracted from the following project documents: KCP-GNS-PCD-STU-0001
Basis of Design for Studies - Phase 1A [S1]
KCP-GNS-DES-DPR-0003
Offshore Pipeline Project Data [S2]
KCP-GNS-DES-DPR-0006
Onshore Pipeline Project Data [S3]
KCP-GNS-PLD-REP-0008
Wall Thickness Report - Phase 1A [S4]
3.1 Linepipe Properties To facilitate pigging operations, the pipeline will have a constant ID. The wall thickness was initially selected for the offshore pipeline section [S4] where the pipe wall thickness and inside diameter were determined for a given nominal pipe outside diameter and steel grade. The pipeline properties used for the wall thickness calculations are summarised in Table 3.1-a. Description
Unit
Value
Defined Nominal Pipeline Diameter
inch
36.0 (914.0mm)
(1)
mm
Inside Diameter
872.8
869.6
Manufacturing Tolerance
mm
1.5
Corrosion Allowance
mm
1.5
Material Grade Specified Minimum Yield Strength (SMYS) Steel Density Young’s Modulus Table 3.1-a
856.8
SAWL, ISO 3183 L450M MPa
450 / 438
kg/m3
7850
MPa
207000
(2)
Linepipe Properties
Note 1:
ID for design pressure options of 120barg, 150barg (base case) and 200barg respectively.
Note 2:
De-rated SMYS for 70degC design temperature in accordance with the requirements of DNV OS-F101 [M4].
Kingsnorth CCS De monstration Pro ject The information contained in this document (the Infor ma tion) is provided in good faith. E.ON UK plc, its subcontractors, subsidiaries, affiliates, e mployees, advisers, and the Depart ment of Energy and Climate Chan ge (DECC) make no representation or warranty as to the accuracy, reliability or completeness of the Infor mation and neither E.ON UK plc nor any of its subcontractors, subsidiaries, affiliates, e mployees, advisers or DECC shall have any liability whatsoever fo r any direct or indirect loss howsoe ver arising from the use of the Infor mation by any party.
KCP-GNS-PLD-DRP-0004 Rev: 03 Project Title:
Kingsnorth Carbon Capture & Storage Project
Document Title:
Onshore Pipeline Mechanical Design Report
Page 8 of 31
3.2 Operating Data The pipeline operating data used for the analysis are summarised in Table 3.2-a below. Description
Unit
Fluid Category
Value
(1)
E
Design Pressure
barg
120
150
200
Maximum Allowable Operating Pressure (MAOP)
barg
HOLD1
HOLD1
HOLD1
Design Temperature
degC
70.0
degC
40.0 (HOLD2)
Maximum Operating Temperature Contents Density – Dense Phase Table 3.2-a
(2)
kg/m
3
597.13
669.38
742.26
Operating Data
Note 1:
In accordance with the Basis of Design for Studies – Phase 1A [S1], the dense phase CO2 anticipated to be produced from the Kingsnorth power station will be classified as Category E substance under PD 8010-1 [M2] toxic fluids that are gases at ambient temperature and atmospheric pressure conditions and are conveyed as gases and / or liquids.
Note 2:
Contents density at maximum inlet temperature of 40degC (dense phase).
3.3 Environmental Data The environmental data used for the analysis is summarised in Table 3.3-a. Description
Unit
Value
Ground Water Density
kg/m3
1025
Soil Density
kg/m3
1950 (HOLD3)
Installation Temperature
degC
11.0
Table 3.3-a
Environmental Data
3.4 External Corrosion Protection The buried sections of the onshore pipeline shall be protected against external corrosion using an appropriate anti-corrosion coating. Typical properties for a 3 layer polyethylene (3LPE) coating are presented in Table 3.4-a. Coating Type
3LPE Table 3.4-a
Nominal Thickness mm
Density kg/cu.m
Thermal Conductivity W/mK
3.2
950
0.35
Anti-Corrosion Coating Properties
Kingsnorth CCS De monstration Pro ject The information contained in this document (the Infor ma tion) is provided in good faith. E.ON UK plc, its subcontractors, subsidiaries, affiliates, e mployees, advisers, and the Depart ment of Energy and Climate Chan ge (DECC) make no representation or warranty as to the accuracy, reliability or completeness of the Infor mation and neither E.ON UK plc nor any of its subcontractors, subsidiaries, affiliates, e mployees, advisers or DECC shall have any liability whatsoever fo r any direct or indirect loss howsoe ver arising from the use of the Infor mation by any party.
KCP-GNS-PLD-DRP-0004 Rev: 03 Project Title:
Kingsnorth Carbon Capture & Storage Project
Document Title:
Onshore Pipeline Mechanical Design Report
4
Page 9 of 31
Mechanical Calculations Mechanical design calculations have been carried out for the onshore sections of the buried Kingsnorth CCS pipeline. The purpose of the mechanical design calculations is to verify the wall thickness of the pipeline and to ascertain the strength and stability of the pipeline under the various loading conditions envisaged during installation and operation. Calculations for the 150barg design pressure option (base case) are included in Appendix A. 4.1 Wall Thickness Calculations The pipeline wall thickness has been determined in accordance with Clause 6.2.2.1 of PD 8010-1 [M2]. This clause requires that the wall thickness shall be capable of withstanding the load exerted on the wall of the pipeline by the fluid internal pressure. The resulting circumferential (hoop) stress shall not exceed the specified minimum yield stress of the pipe material by a factor applicable to the installation location. Design factors for the onshore pipeline will depend on the population density. For pipelines intended to convey category E fluids, the design factor should under normal circumstances not exceed 0.72 in Class 1 locations (population density less than 2.5 persons per hectare). In Class 2 locations (population density greater than 2.5 persons per hectare) a design factor of 0.3 shall apply. A design factor of 0.3 shall also apply at major / minor road crossings, railway crossings and at fabricated assemblies ie pig traps, block valves, subject to a risk assessment. The corrosion allowance and manufacturing tolerance is added to the calculated wall thickness to determine the nominal wall thickness. In accordance with standard industry practice, the outside diameter to wall thickness ratio (D/t), where t is the minimum wall thickness (excluding corrosion allowance and manufacturing tolerance), should not exceed 96 unless it can be demonstrated that higher values are not detrimental to the construction and in-situ integrity of the pipeline. As discussed in (3.1), to facilitate pigging operations, the pipeline will have a constant ID. For ease of analysis, the wall thickness is selected initially for the offshore pipeline section where the pipe wall thickness and inside diameter are determined for a given nominal pipe outside diameter and steel grade. The inside diameter of the pipeline is then maintained for the remaining sections. Description
Unit
Design Pressure
barg
120.0
150.0
200.0
120.0
150.0
200.0
Required Inside Diameter
mm
872.8
869.6
856.8
872.8
869.6
856.8
Calculated Nominal Wall Thickness
mm
20.39
24.89
32.22
47.17
56.20
74.53
Selected Wall Thickness
mm
20.6
25.4
32.4
47.3
56.3
74.6
Outside Diameter
mm
914.0
920.4
921.6
967.4
982.2
1006.0
Table 4.1-a
Design Factor 0.72
Design Factor 0.30
Wall Thickness Results
The nominal wall thickness is also assessed for the capacity to withstand additional loading to which the pipeline will be subjected during installation and operation. In accordance with Clause 6.4.2.5 of PD 8010-1 [M2], the resulting stresses are then combined by the Von Mises yield criterion in the form of an equivalent stress. The value of the resulting equivalent stress shall not exceed the allowable equivalent stress as defined in Clause Kingsnorth CCS De monstration Pro ject The information contained in this document (the Infor ma tion) is provided in good faith. E.ON UK plc, its subcontractors, subsidiaries, affiliates, e mployees, advisers, and the Depart ment of Energy and Climate Chan ge (DECC) make no representation or warranty as to the accuracy, reliability or completeness of the Infor mation and neither E.ON UK plc nor any of its subcontractors, subsidiaries, affiliates, e mployees, advisers or DECC shall have any liability whatsoever fo r any direct or indirect loss howsoe ver arising from the use of the Infor mation by any party.
KCP-GNS-PLD-DRP-0004 Rev: 03 Project Title:
Kingsnorth Carbon Capture & Storage Project
Document Title:
Onshore Pipeline Mechanical Design Report
Page 10 of 31
6.4.3.2 of PD 8010-1 [M2]. The stress calculations for the operational phase have been carried out using the pipe nominal wall thickness. 4.2 Circumferential Stresses Circumferential stresses are developed in the wall of the pipeline as a result of hydrostatic pressure testing and operational conditions. These stresses are calculated together with other stresses and included in the overall stress assessment of the pipeline for the installation and operational conditions to which the pipeline will be subjected. Internal pressure will produce circumferential tensile stresses in the wall of the pipeline (hoop stress). The Barlow equation as defined in Clause 6.4.2.1 of PD 8010-1 [M2] was used to calculate the stresses for the selected wall thickness and the results are shown in Tables 4.2.2-a and 4.2.2-b. For the operating condition the design pressure is used. For the hydrostatic pressure test the internal pressure is taken as 150% of the design pressure. Description
Unit
Design Pressure
barg
120
150
200
Circumferential Stress due to Internal Pressure (Operating)
N/mm2
266.2
271.8
284.4
Circumferential Stress due to Internal Pressure (Hydrostatic test)
N/mm2
399.3
407.7
426.7
Table 4.2-a
Design Factor 0.72
Circumferential Stress (DF 0.72)
Description
Unit
Design Pressure
barg
120
150
200
Circumferential Stress due to Internal Pressure (Operating)
N/mm2
117.0
123.8
125.7
Circumferential Stress due to Internal Pressure (Hydrostatic test)
N/mm2
175.5
185.7
188.5
Table 4.2-b
Design Factor 0.30
Circumferential Stress (DF 0.30)
4.3 Longitudinal Stresses for Fully Restrained Pipeline Pipelines tend to expand or contract in the longitudinal direction under the effect of internal pressure and thermal expansion. Internal pressure results in the pipe contracting in the longitudinal direction due to Poisson’s Ratio effect. An increase in pipe temperature compared to the temperature at which the pipeline was installed causes the pipe to expand due to the effect of linear thermal expansion for the pipe material. It follows that a decrease in temperature below the installation temperature will cause the pipe to reduce in length. For buried pipelines, the surrounding soil friction forces will resist this longitudinal expansion/contraction and for relatively long straight sections of pipeline the surrounding soil will manage to exercise full restraint on the pipeline until there is zero strain in the pipeline. The restraint of the soil against the tendency of the pipe to shrink because of the internal pressure effect produces longitudinal tensile stress in the wall of the pipe. The soil restraint against the thermally induced tendency to elongate the pipe will cause longitudinal compressive stresses. The resultant longitudinal stress will be the algebraic sum of these two longitudinal stresses. The thermally induced longitudinal stress for the operating case was calculated using an installation temperature of 11degC and the design temperature of 70degC. A lower installation temperature will lead to a higher longitudinal compressive Kingsnorth CCS De monstration Pro ject The information contained in this document (the Infor ma tion) is provided in good faith. E.ON UK plc, its subcontractors, subsidiaries, affiliates, e mployees, advisers, and the Depart ment of Energy and Climate Chan ge (DECC) make no representation or warranty as to the accuracy, reliability or completeness of the Infor mation and neither E.ON UK plc nor any of its subcontractors, subsidiaries, affiliates, e mployees, advisers or DECC shall have any liability whatsoever fo r any direct or indirect loss howsoe ver arising from the use of the Infor mation by any party.
KCP-GNS-PLD-DRP-0004 Rev: 03 Project Title:
Kingsnorth Carbon Capture & Storage Project
Document Title:
Onshore Pipeline Mechanical Design Report
Page 11 of 31
stress. Tensile longitudinal stress in the presence of tensile circumferential stress is not detrimental to the strength of the pipe as long as it is less in value than the circumferential tensile stress. It is the compressive longitudinal stress in the presence of tensile circumferential stress, which restricts the strength capacity of the pipe. The calculated longitudinal stresses for a fully restrained pipeline are shown in Tables 4.3-a and 4.3-b. A negative longitudinal stress is compressive. The calculated equivalent stress and the minimum allowable radius of curvature for a fully restrained line are shown in Tables 4.4-a and 4.4-b. Description
Unit
Design Pressure
barg
120
150
200
N/mm2
-99.5
-107.9
-111.5
Total Longitudinal Stress Table 4.3-a
Design Factor 0.72
Longitudinal Operating Stress for Fully Restrained Pipeline (DF 0.72)
Description
Unit
Design Pressure
barg
120
150
200
N/mm2
-159.1
-160.5
-163.7
Total Longitudinal Stress Table 4.3-b
Design Factor 0.30
Longitudinal Operating Stress for Fully Restrained Pipeline (DF 0.30)
4.4 Equivalent Stress for Fully Restrained Pipeline After determining the total circumferential and total longitudinal stresses acting in the wall of the pipeline (for fully restrained conditions), the resulting equivalent stress is calculated using the Von Mises yield criterion. The resulting equivalent stress should not exceed the maximum equivalent stress which is 90% of the material SMYS. The difference between the calculated equivalent stress and the maximum allowable equivalent stress can be allocated as available longitudinal stress which can be used to accommodate longitudinal bending stresses induced in the wall of the pipeline as a result of gentle terrain undulations along the pipeline route. Any undulation or horizontal curve along the pipeline route which will have a radius of curvature larger than the calculated minimum radius of curvature can be accommodated within the elastic range of the pipe material. Undulations or other curves along the pipeline route that require radii of curvature less than the calculated elastic minimum radius of curvature will have to be made with the use of hot formed bends or cold formed field bends as appropriate. Hot formed bends (shop fabricated) shall have a minimum radius of 5D. The calculated equivalent stress is shown in Tables 4.4-a and 4.4-b. Description
Unit
Design Pressure
barg
Max Allowable Equivalent Stress
N/mm2
Equivalent Stress
N/mm2
Table 4.4-a
Design Factor 0.72 120
150
200
394.2 327.5
338.9
353.6
Equivalent Operating Stress for Fully Restrained Pipeline (DF 0.72)
Kingsnorth CCS De monstration Pro ject The information contained in this document (the Infor ma tion) is provided in good faith. E.ON UK plc, its subcontractors, subsidiaries, affiliates, e mployees, advisers, and the Depart ment of Energy and Climate Chan ge (DECC) make no representation or warranty as to the accuracy, reliability or completeness of the Infor mation and neither E.ON UK plc nor any of its subcontractors, subsidiaries, affiliates, e mployees, advisers or DECC shall have any liability whatsoever fo r any direct or indirect loss howsoe ver arising from the use of the Infor mation by any party.
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Document Title:
Onshore Pipeline Mechanical Design Report
Description
Unit
Design Pressure
barg
Max Allowable Equivalent Stress
N/mm2
Equivalent Stress
N/mm2
Table 4.4-b
Page 12 of 31
Design Factor 0.30 120
150
200
394.2 204.7
246.9
251.3
Equivalent Operating Stress for Fully Restrained Pipeline (DF 0.30)
4.5 Anchor Force and Displacement, Partly Restrained Pipeline At termination points, the soil can no longer maintain full restraint on the buried sections of pipeline upstream of the termination point. These sections are identified as partly restrained sections. Sections upstream of termination points, the displacement is in the direction of the termination point. If the pipeline displacements at these locations are unacceptable or the stresses at the bends become unacceptably high, the displacements can be prevented by installing anchor blocks on the straight section of the pipeline just prior to the termination point. The force required to fully restrain the displacement of the pipeline at these locations is defined as the anchor force. The length of the partly restrained sections is dependant on the pipe and soil interaction. The length of the partly restrained moving section, called the active length is determined as a function of the anchor force and the friction force applied by the surrounding soil on the pipeline. Here, the anchor force is defined as the potential force that would be required to restrain the pipeline, since anchoring the pipeline will eliminate displacement. The friction force will depend on the backfill soil load, the pipe parameters and operating conditions. For the thermally induced loads a maximum operating temperature of 40degC has been used in preference to the design temperature of 70degC as this most closely represents the continuous as installed condition. It is assumed that excursions above 40degC would be under fault conditions and only for a short period of time. Anchor force, active length, end displacement have been determined for the operating load case in the un-corroded state as required by Clause 6.4.2.2 of PD 8010-1 [M2]. The results are shown in Tables 4.5-a and 4.5-b. Description
Unit
Design Pressure
barg
120
150
200
kN
7,050
8,724
11,131
m
190.0
229.0
285.0
mm
55.8
67.3
84.7
Anchor Force Active Length End Displacement Table 4.5-a
(1)
Design Factor 0.72
Anchor Force, Active Length and End Displacement (DF 0.72)
Description
Unit
Design Pressure
barg
120
150
200
kN
12,718
15,357
20,332
m
301.0
343.0
429.0
mm
67.6
78.8
96.5
Anchor Force Active Length End Displacement Table 4.5-b Note 1:
(1)
Design Factor 0.30
Anchor Force, Active Length and End Displacement (DF 0.30)
Assumes that the pipeline is not anchored, long and in dry conditions.
Kingsnorth CCS De monstration Pro ject The information contained in this document (the Infor ma tion) is provided in good faith. E.ON UK plc, its subcontractors, subsidiaries, affiliates, e mployees, advisers, and the Depart ment of Energy and Climate Chan ge (DECC) make no representation or warranty as to the accuracy, reliability or completeness of the Infor mation and neither E.ON UK plc nor any of its subcontractors, subsidiaries, affiliates, e mployees, advisers or DECC shall have any liability whatsoever fo r any direct or indirect loss howsoe ver arising from the use of the Infor mation by any party.
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Document Title:
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Page 13 of 31
4.6 Anti-buoyancy Assessment The pipeline has been assessed for the possibility of flotation in areas of high water table with a density of 1025kg/m3 (seawater). The results show that the pipeline in the empty condition may experience flotation if it is not provided with additional weighting. The continuous concrete coating thickness was determined using concrete with a unit weight of 3040kg/m3. A safety factor of 1.1 is employed. The required continuous concrete coating thicknesses are summarised in Table 4.6-a. Description
Unit
Design Pressure
barg
120.0
150.0
200.0
Calculated Coating Thickness
mm
49.4
33.2
7.6
Table 4.6-a
Design Factor 0.72
Design Factor 0.30
(1)
120.0 -43.5
(2)
150.0 -78.6
(2)
200.0 -159.1
(2)
Continuous Concrete Coating Thickness
Note 1:
For manufacturing purposes the minimum thickness of continuous concrete weight coating is limited to 25mm. Intermediate set-on saddle weights could be employed as an alternative.
Note 2:
A negative result indicates that concrete coating is not required and there is sufficient weight in the pipeline to resist floatation.
4.7 Upheaval Buckling The guideline method from 1990 OTC paper No. 6335 [S6] has been used to assess the propensity of the pipeline for upheaval buckling. Imperfections of up to 0.3 m height were evaluated and the results presented in Table 4.7-a show that the pipeline is unlikely to experience upheaval buckling for the cases considered. The effects of continuous concrete weight coating are ignored. Required Depth of Cover (m)
Description
Unit
Design Pressure
barg
120.0
150.0
200.0
120.0
150.0
200.0
Wall Thickness
mm
20.6
25.4
32.4
47.3
56.3
74.6
-0.33
-0.38
-0.45
-0.63
-0.73
-0.94
-0.29
-0.33
-0.39
-0.58
-0.67
-0.86
-0.24
-0.28
-0.32
-0.49
-0.56
-0.71
-0.21
-0.23
-0.26
-0.42
-0.48
-0.61
0.05 Imperfection Height
0.10 0.20 0.30
Table 4.7-a
m
Design Factor 0.72
Design Factor 0.30
Relationship between Imperfection Height and Depth of Cover
The negative sign in front of the required depth of cover indicates that pipeline does not require burial to counter upheaval buckling.
Kingsnorth CCS De monstration Pro ject The information contained in this document (the Infor ma tion) is provided in good faith. E.ON UK plc, its subcontractors, subsidiaries, affiliates, e mployees, advisers, and the Depart ment of Energy and Climate Chan ge (DECC) make no representation or warranty as to the accuracy, reliability or completeness of the Infor mation and neither E.ON UK plc nor any of its subcontractors, subsidiaries, affiliates, e mployees, advisers or DECC shall have any liability whatsoever fo r any direct or indirect loss howsoe ver arising from the use of the Infor mation by any party.
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Document Title:
Onshore Pipeline Mechanical Design Report
Page 14 of 31
4.8 API RP 1102 Road Crossing Assessment To ensure safe operation, the stresses affecting the pipeline at a road crossing must be accounted for, which includes both circumferential and longitudinal stresses. The recommended design procedure for determining the acceptability of the stresses is given in API RP 1102, Steel pipeline crossing railroads and highways [M6]. The pipeline will be subjected to both internal load due to pressure and external loads from earth forces (dead load) and highway traffic (live load). Other loads may be present as a result of temperature fluctuations caused by changes in season; longitudinal tension due to end effects; fluctuations associated with pipeline operating conditions; unusual surface loads associated with the movement of specialised equipment and ground deformation as a result of shrinking and swelling soils, local instability etc. Pipe stresses as a result of temperature fluctuations can be included in the analysis; all other loads are a result of special conditions. Loads of this nature are site specific and as such have not been included as part of this assessment. The assessment calculations shown in Appendix B, show that the proposed wall thicknesses for a design factor of 0.3 as presented in Table 4.1-a, satisfy the stress criteria of API RP 1102 [M6] for uncased installation at an unpaved highway.
Kingsnorth CCS De monstration Pro ject The information contained in this document (the Infor ma tion) is provided in good faith. E.ON UK plc, its subcontractors, subsidiaries, affiliates, e mployees, advisers, and the Depart ment of Energy and Climate Chan ge (DECC) make no representation or warranty as to the accuracy, reliability or completeness of the Infor mation and neither E.ON UK plc nor any of its subcontractors, subsidiaries, affiliates, e mployees, advisers or DECC shall have any liability whatsoever fo r any direct or indirect loss howsoe ver arising from the use of the Infor mation by any party.
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Document Title:
Onshore Pipeline Mechanical Design Report
5
Page 15 of 31
Mandatory References The design, fabrication and construction of the pipeline system shall be in accordance with the latest revisions of the following specifications, codes and standards unless stated otherwise. 5.1 Codes and Standards [M1] BS EN 14161
Petroleum and Natural Gas Industries Pipeline Transportation Systems;
[M2] PD 8010-1
Code of Practice for Pipelines - Part 1: Steel Pipelines on Land;
[M3] ISO 3183 / API 5L
Petroleum and Natural Gas Industries - Steel Pipe for Pipeline Transportation Systems;
[M4] DNV OS-F101
Submarine Pipeline Systems;
[M5] ASME B31.4
Pipeline Transportation Systems for Liquid Hydrocarbons & Other Liquids;
[M6] API RP 1102
Steel pipeline crossing railroads and highways;
[M7] DNV-RP-J202
Design and Operation of CO2 Pipelines;
[M8] ISO 13623
Petroleum & Natural Gas Industries - Pipeline Transportation Systems;
Kingsnorth CCS De monstration Pro ject The information contained in this document (the Infor ma tion) is provided in good faith. E.ON UK plc, its subcontractors, subsidiaries, affiliates, e mployees, advisers, and the Depart ment of Energy and Climate Chan ge (DECC) make no representation or warranty as to the accuracy, reliability or completeness of the Infor mation and neither E.ON UK plc nor any of its subcontractors, subsidiaries, affiliates, e mployees, advisers or DECC shall have any liability whatsoever fo r any direct or indirect loss howsoe ver arising from the use of the Infor mation by any party.
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Document Title:
Onshore Pipeline Mechanical Design Report
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Page 16 of 31
Supporting References 6.1 Project Documentation [S1]
KCP-GNS-PCD-STU-0001
Basis of Design for Studies - Phase 1A;
[S2]
KCP-GNS-DES-DPR-0003
Offshore Pipeline Project Data;
[S3]
KCP-GNS-DES-DPR-0006
Onshore Pipeline Project Data;
[S4]
KCP-GNS-PLD-REP-0008
Wall Thickness Report - Phase 1A;
[S5]
KCP-EEN-PCD-DPR-0001
Overall Project Units;
6.2 External Documentation [S6]
OTC Paper 6335, 1990
Design of Submarine Pipelines Against Upheaval Buckling;
Kingsnorth CCS De monstration Pro ject The information contained in this document (the Infor ma tion) is provided in good faith. E.ON UK plc, its subcontractors, subsidiaries, affiliates, e mployees, advisers, and the Depart ment of Energy and Climate Chan ge (DECC) make no representation or warranty as to the accuracy, reliability or completeness of the Infor mation and neither E.ON UK plc nor any of its subcontractors, subsidiaries, affiliates, e mployees, advisers or DECC shall have any liability whatsoever fo r any direct or indirect loss howsoe ver arising from the use of the Infor mation by any party.
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Document Title:
Onshore Pipeline Mechanical Design Report
7
Page 17 of 31
Appendix A, PD 8010-1 Mechanical Design Calculations The extracts from the mechanical design calculations for the 150barg design pressure option are presented below: 7.1 Wall Thickness Genesis Oil and Gas Ltd
CALCULATION SHEET
Client
By
E.ON
Checked
Page
NJ
Project
Date
Kingsnorth CCS - Onshore Pipeline
of
AA Rev.
Ref.
22/07/2010
1
Subject
PD 8010 Wall Thickness Verification
Parameter
Units
Input
PD 8010 Pressure Containment
BASE CASE API 5L X65 150barg 0.72 DF
BASE CASE API 5L X65 150barg 0.30 DF
BASE CASE API 5L X70 150barg 0.72 DF
BASE CASE API 5L X70 150barg 0.30 DF
Wall Thickness Design Outside Diameter SMYS derated @ operating Tº Choose Mill Tolerance in mm or % Mill Tolerance Mill Tolerance Corrosion Allowance Design Pressure @ Elevation (rel to LAT) Contents Density Water Depth (LAT) Minimum Water Depth Seawater Density Hoop Stress Design Factor
mm MPa % mm mm barg m kg/m3 m m kg/m3 %
920.4 438 mm 12.5% 1.5 1.5 150 0 669.4 0 0 0 72%
982.2 438 mm 12.5% 1.5 1.5 150 0 669.4 0 0 0 30%
917.2 473 mm 12.5% 1.5 1.5 150 0 669.4 0 0 0 72%
974.2 473 mm 12.5% 1.5 1.5 150 0 669.4 0 0 0 30%
Internal Pressure Pi Min External Pressure Po
barg barg
150.0 0.0
150.0 0.0
150.0 0.0
150.0 0.0
Thin Wall Thickness Min Wall Thickness D/t Ratio WT+CA+MT
mm mm
21.9 42.0 24.89
56.1 17.5 59.06
20.2 45.4 23.20
51.5 18.9 54.49
Thick Wall Thickness Internal diameter Min Wall Thickness D/t Ratio WT+CA+MT
m mm mm
0.8776 21.4 43.0 24.39
0.8758 53.2 18.5 56.20
0.8777 19.8 46.4 22.77
0.8761 49.0 19.9 52.04
Hydrotest Design Selected API Size Inside diameter Select WT Type SMYS @ ambiant Tº Contents Density for Hydrotest Hoop Stress Design Factor
mm mm MPa kg/m3 %
25.40 869.60 Thin Wall Thickness 450 1025 90%
Internal Diameter - Mill Tol Hydrotest Pressure (90% σh) Hydrotest Pressure (1.5 x DP) Selected Hydrotest Pressure
mm barg barg barg
872.6 210.3 225 210
56.30 23.80 52.30 869.60 869.60 869.60 Thick Wall Thickness Thin Wall ThicknessThick Wall Thickness 450 485 485 1025 1025 1025 90% 90% 90% 872.6 477.0 225 225
872.6 212.3 225 212
872.6 478.8 225 225
Kingsnorth CCS De monstration Pro ject The information contained in this document (the Infor ma tion) is provided in good faith. E.ON UK plc, its subcontractors, subsidiaries, affiliates, e mployees, advisers, and the Depart ment of Energy and Climate Chan ge (DECC) make no representation or warranty as to the accuracy, reliability or completeness of the Infor mation and neither E.ON UK plc nor any of its subcontractors, subsidiaries, affiliates, e mployees, advisers or DECC shall have any liability whatsoever fo r any direct or indirect loss howsoe ver arising from the use of the Infor mation by any party.
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Document Title:
Onshore Pipeline Mechanical Design Report
Page 18 of 31
7.2 Expansion
Kingsnorth CCS De monstration Pro ject The information contained in this document (the Infor ma tion) is provided in good faith. E.ON UK plc, its subcontractors, subsidiaries, affiliates, e mployees, advisers, and the Depart ment of Energy and Climate Chan ge (DECC) make no representation or warranty as to the accuracy, reliability or completeness of the Infor mation and neither E.ON UK plc nor any of its subcontractors, subsidiaries, affiliates, e mployees, advisers or DECC shall have any liability whatsoever fo r any direct or indirect loss howsoe ver arising from the use of the Infor mation by any party.
KCP-GNS-PLD-DRP-0004 Rev: 03 Project Title:
Kingsnorth Carbon Capture & Storage Project
Document Title:
Onshore Pipeline Mechanical Design Report
Page 19 of 31
Kingsnorth CCS De monstration Pro ject The information contained in this document (the Infor ma tion) is provided in good faith. E.ON UK plc, its subcontractors, subsidiaries, affiliates, e mployees, advisers, and the Depart ment of Energy and Climate Chan ge (DECC) make no representation or warranty as to the accuracy, reliability or completeness of the Infor mation and neither E.ON UK plc nor any of its subcontractors, subsidiaries, affiliates, e mployees, advisers or DECC shall have any liability whatsoever fo r any direct or indirect loss howsoe ver arising from the use of the Infor mation by any party.
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Kingsnorth Carbon Capture & Storage Project
Document Title:
Onshore Pipeline Mechanical Design Report
Page 20 of 31
Kingsnorth CCS De monstration Pro ject The information contained in this document (the Infor ma tion) is provided in good faith. E.ON UK plc, its subcontractors, subsidiaries, affiliates, e mployees, advisers, and the Depart ment of Energy and Climate Chan ge (DECC) make no representation or warranty as to the accuracy, reliability or completeness of the Infor mation and neither E.ON UK plc nor any of its subcontractors, subsidiaries, affiliates, e mployees, advisers or DECC shall have any liability whatsoever fo r any direct or indirect loss howsoe ver arising from the use of the Infor mation by any party.
KCP-GNS-PLD-DRP-0004 Rev: 03 Project Title:
Kingsnorth Carbon Capture & Storage Project
Document Title:
Onshore Pipeline Mechanical Design Report
Page 21 of 31
Kingsnorth CCS De monstration Pro ject The information contained in this document (the Infor ma tion) is provided in good faith. E.ON UK plc, its subcontractors, subsidiaries, affiliates, e mployees, advisers, and the Depart ment of Energy and Climate Chan ge (DECC) make no representation or warranty as to the accuracy, reliability or completeness of the Infor mation and neither E.ON UK plc nor any of its subcontractors, subsidiaries, affiliates, e mployees, advisers or DECC shall have any liability whatsoever fo r any direct or indirect loss howsoe ver arising from the use of the Infor mation by any party.
KCP-GNS-PLD-DRP-0004 Rev: 03 Project Title:
Kingsnorth Carbon Capture & Storage Project
Document Title:
Onshore Pipeline Mechanical Design Report
Page 22 of 31
Kingsnorth CCS De monstration Pro ject The information contained in this document (the Infor ma tion) is provided in good faith. E.ON UK plc, its subcontractors, subsidiaries, affiliates, e mployees, advisers, and the Depart ment of Energy and Climate Chan ge (DECC) make no representation or warranty as to the accuracy, reliability or completeness of the Infor mation and neither E.ON UK plc nor any of its subcontractors, subsidiaries, affiliates, e mployees, advisers or DECC shall have any liability whatsoever fo r any direct or indirect loss howsoe ver arising from the use of the Infor mation by any party.
KCP-GNS-PLD-DRP-0004 Rev: 03 Project Title:
Kingsnorth Carbon Capture & Storage Project
Document Title:
Onshore Pipeline Mechanical Design Report
Page 23 of 31
Kingsnorth CCS De monstration Pro ject The information contained in this document (the Infor ma tion) is provided in good faith. E.ON UK plc, its subcontractors, subsidiaries, affiliates, e mployees, advisers, and the Depart ment of Energy and Climate Chan ge (DECC) make no representation or warranty as to the accuracy, reliability or completeness of the Infor mation and neither E.ON UK plc nor any of its subcontractors, subsidiaries, affiliates, e mployees, advisers or DECC shall have any liability whatsoever fo r any direct or indirect loss howsoe ver arising from the use of the Infor mation by any party.
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Document Title:
Onshore Pipeline Mechanical Design Report
Page 24 of 31
7.3 Upheaval Buckling
Kingsnorth CCS De monstration Pro ject The information contained in this document (the Infor ma tion) is provided in good faith. E.ON UK plc, its subcontractors, subsidiaries, affiliates, e mployees, advisers, and the Depart ment of Energy and Climate Chan ge (DECC) make no representation or warranty as to the accuracy, reliability or completeness of the Infor mation and neither E.ON UK plc nor any of its subcontractors, subsidiaries, affiliates, e mployees, advisers or DECC shall have any liability whatsoever fo r any direct or indirect loss howsoe ver arising from the use of the Infor mation by any party.
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Document Title:
Onshore Pipeline Mechanical Design Report
Page 25 of 31
7.4 Specific Gravity (Bouyancy) Pipe OD Wall thickness Steel density Seawater density Contents Density
Layer 1:3LPE Layer 2: Concrete Layer 3:Solid PP Layer 4: PP Foam Layer 5: Solid PP
mm mm kg/m3 kg/m3 kg/m3 Density (kg/m3) 950 3040 900 740 900
Overall OD
Pipe Contents Water Option 1 Layer 1 Layer 2 Layer 3 Layer 4 Layer 5
920.4 25.40 7850 1025 669.38 Thk mm 3.20 33.15 0.00 0.00 0.00
Layer 1:3LPE Layer 2: Concrete Layer 3 Solid PP Layer 4: PP Foam Layer 5: Solid PP
993.0968
mm mm kg/m3 kg/m3 kg/m3 Density (kg/m3) 950 3040 900 740 900
Overall OD
ID m 0 8696
OD m 0 9204 0 8696 0 8696
Area m2 0 0714 0 5939 0 5939
0 9204 0 9268 0 9930968 0 9930968 0 9930968
0 9268 0 99309682 0 99309682 0 99309682 0 99309682
0 0093 0 1000 0 0000 0 0000 0 0000
Dry weight empty Dry weight pipe + contents Bouyancy force Submerged weight pipe empty Submerged weight pipe + water Submerged weight pipe + contents
SG submerged empty water contents
Pipe OD Wall thickness Steel density Seawater density Contents Density
Weight/m kg/m N/m 560 630 5499 780 Pipe 397 5591 3900 055 Contents 608 7694 5972 028 Water Option 1 8 821 86 532 Layer 1 303 902 2981 282 Layer 2 0 000 0 000 Layer 3 0 000 0 000 Layer 4 0 000 0 000 Layer 5 873 353 1270 912 793 957 79 396 688 166 476.955
8567 594 12467 648 7788 717 778 876 6750 904 4678 931
982.2 56.30 7850 1025 669 38 Thk mm 3.20 -78.54 0.00 0.00 0.00 831.5175
ID m 0 8696
OD m 0 9822 0 8696 0 8696
Area m2 0 1638 0 5939 0 5939
0 9822 0 9886 0 8315175 0 8315175 0 8315175
0 9886 0 83151747 0 83151747 0 83151747 0 83151747
0 0099 -0 2246 0 0000 0 0000 0 0000
Dry weight empty Dry weight pipe + contents Bouyancy force Submerged weight pipe empty Submerged weight pipe + water Submerged weight pipe + contents
SG submerged 1 100 empty 1 867 water 1 601 contents
Weight/m kg/m N/m 1285 559 12611 334 397 5591 3900 055 608 7694 5972 028 9 411 -682 638 0 000 0 000 0 000
92 322 -6696 684 0 000 0 000 0 000
612 331 1009 891 556 617 55 714 664 484 453.274
6006 972 9907 027 5460 413 546 559 6518 587 4446 613
1 100 2 194 1 814
Kingsnorth CCS De monstration Pro ject The information contained in this document (the Infor ma tion) is provided in good faith. E.ON UK plc, its subcontractors, subsidiaries, affiliates, e mployees, advisers, and the Depart ment of Energy and Climate Chan ge (DECC) make no representation or warranty as to the accuracy, reliability or completeness of the Infor mation and neither E.ON UK plc nor any of its subcontractors, subsidiaries, affiliates, e mployees, advisers or DECC shall have any liability whatsoever fo r any direct or indirect loss howsoe ver arising from the use of the Infor mation by any party.
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Onshore Pipeline Mechanical Design Report
8
Page 26 of 31
Appendix B, API RP 1102 Uncased Road Crossing Assessment
Kingsnorth CCS De monstration Pro ject The information contained in this document (the Infor ma tion) is provided in good faith. E.ON UK plc, its subcontractors, subsidiaries, affiliates, e mployees, advisers, and the Depart ment of Energy and Climate Change (DECC) make no representation or warranty as to the accuracy, reliability or completeness of the Infor mation and neither E.ON UK plc nor any of its subcontractors, subsidiaries, affiliates, e mployees, advisers or DECC shall have any liability whatsoever for any direct or indirect loss howsoe ver arising from the use of the Infor mation by any party.
KCP-GNS-PLD-DRP-0004 Rev: 03 Project Title:
Kingsnorth Carbon Capture & Storage Project
Document Title:
Onshore Pipeline Mechanical Design Report
Page 27 of 31
Kingsnorth CCS De monstration Pro ject The information contained in this document (the Infor ma tion) is provided in good faith. E.ON UK plc, its subcontractors, subsidiaries, affiliates, e mployees, advisers, and the Depart ment of Energy and Climate Chan ge (DECC) make no representation or warranty as to the accuracy, reliability or completeness of the Infor mation and neither E.ON UK plc nor any of its subcontractors, subsidiaries, affiliates, e mployees, advisers or DECC shall have any liability whatsoever fo r any direct or indirect loss howsoe ver arising from the use of the Infor mation by any party.
KCP-GNS-PLD-DRP-0004 Rev: 03 Project Title:
Kingsnorth Carbon Capture & Storage Project
Document Title:
Onshore Pipeline Mechanical Design Report
Page 28 of 31
Kingsnorth CCS De monstration Pro ject The information contained in this document (the Infor ma tion) is provided in good faith. E.ON UK plc, its subcontractors, subsidiaries, affiliates, e mployees, advisers, and the Depart ment of Energy and Climate Chan ge (DECC) make no representation or warranty as to the accuracy, reliability or completeness of the Infor mation and neither E.ON UK plc nor any of its subcontractors, subsidiaries, affiliates, e mployees, advisers or DECC shall have any liability whatsoever fo r any direct or indirect loss howsoe ver arising from the use of the Infor mation by any party.
KCP-GNS-PLD-DRP-0004 Rev: 03 Project Title:
Kingsnorth Carbon Capture & Storage Project
Document Title:
Onshore Pipeline Mechanical Design Report
Page 29 of 31
Kingsnorth CCS De monstration Pro ject The information contained in this document (the Infor ma tion) is provided in good faith. E.ON UK plc, its subcontractors, subsidiaries, affiliates, e mployees, advisers, and the Depart ment of Energy and Climate Chan ge (DECC) make no representation or warranty as to the accuracy, reliability or completeness of the Infor mation and neither E.ON UK plc nor any of its subcontractors, subsidiaries, affiliates, e mployees, advisers or DECC shall have any liability whatsoever fo r any direct or indirect loss howsoe ver arising from the use of the Infor mation by any party.
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Kingsnorth Carbon Capture & Storage Project
Document Title:
Onshore Pipeline Mechanical Design Report
9
Page 30 of 31
Appendix C, DNV RP-J202 Wall Thickness Calculations The following presents the wall thicknesses as determined in accordance with Clause 5.4 of DNV RP-J202 [M17] for a ISO 3183 L450M grade material. The results presented in Tables 9.0-a, 9.0-b and 9.0-c are for comparative purposes only and do not form part of the mechanical design detailed herein. This clause requires that the wall thickness shall be capable of withstanding the load exerted on the wall of the pipeline by the fluid pressure. The resulting circumferential (hoop) stress shall not exceed the specified minimum yield stress of the pipe material by a factor applicable to the installation location as defined in Table 5-2 of DNV RP-J202 [M17]. The analysis considers design factors 0.77, 0.67 and 0.55 which are applicable to location classes 2, 3 and 4 respectively as defined in Table B.2 of ISO 13623 [M18]. As discussed in (3.1), to facilitate pigging operations the pipeline is designed with a constant ID which matches the offshore pipeline section. Description
Unit
Design Factor
Value 0.77
0.67
0.55
Inside Diameter
mm
Calculated Nominal Wall Thickness
mm
18.98
21.38
25.52
Selected Wall Thickness
mm
20.60
22.20
27.00
Outside Diameter
mm
914.0
917.20
926.80
Table 9.0-a
872.8
DNV RP-J202 Wall Thickness Requirements (120barg)
Description
Unit
Design Factor
Value 0.77
0.67
0.55
Inside Diameter
mm
Calculated Nominal Wall Thickness
mm
22.95
26.02
31.18
Selected Wall Thickness
mm
23.80
27.00
31.80
Outside Diameter
mm
917.20
923.60
933.20
Table 9.0-b
869.6
DNV RP-J202 Wall Thickness Requirements (150barg, base case)
Description
Unit
Design Factor
Value 0.77
0.67
0.55
Inside Diameter
mm
Calculated Nominal Wall Thickness
mm
29.41
33.45
40.38
Selected Wall Thickness
mm
30.20
33.60
40.50
Outside Diameter
mm
917.20
924.00
937.80
Table 9.0-c
856.8
DNV RP-J202 Wall Thickness Requirements (200barg)
Kingsnorth CCS De monstration Pro ject The information contained in this document (the Infor ma tion) is provided in good faith. E.ON UK plc, its subcontractors, subsidiaries, affiliates, e mployees, advisers, and the Depart ment of Energy and Climate Chan ge (DECC) make no representation or warranty as to the accuracy, reliability or completeness of the Infor mation and neither E.ON UK plc nor any of its subcontractors, subsidiaries, affiliates, e mployees, advisers or DECC shall have any liability whatsoever fo r any direct or indirect loss howsoe ver arising from the use of the Infor mation by any party.
KCP-GNS-PLD-DRP-0004 Rev: 03 Project Title:
Kingsnorth Carbon Capture & Storage Project
Document Title:
Onshore Pipeline Mechanical Design Report
Page 31 of 31
9.1 Extract from Pressure Containment Calculations The pressure containment calculations for the 150barg design pressure option (base case) are presented below: ISO 13623 Pipeline calculations Internal pressure SMYS Corrosion allowance Manufacturing tolerance Design factor Outside diameter Specified minimum wall thickness Nominal wall thickness Selected wall thickness Minimum wall thickness D/t Ratio Inside diameter
Operating P S Ca mt Fh D tmin tnom t t'
15.00 438.00 1.50 1.50 0.77 917.20 19.95 22.95 23.80 20.80 44.10
d
869.60 mm
ISO 13623 Pipeline calculations Internal pressure SMYS Corrosion allowance Manufacturing tolerance Design factor Outside diameter Specified minimum wall thickness Nominal wall thickness Selected wall thickness Minimum wall thickness D/t Ratio Inside diameter
mm mm mm mm mm
Operating P S Ca mt Fh D tmin tnom t t'
15.00 438.00 1.50 1.50 0.67 923.60 23.02 26.02 27.00 24.00 38.48
d
869.60 mm
ISO 13623 Pipeline calculations Internal pressure SMYS Corrosion allowance Manufacturing tolerance Design factor Outside diameter Specified minimum wall thickness Nominal wall thickness Selected wall thickness Minimum wall thickness D/t Ratio Inside diameter
N/mm2 N/mm2 mm mm
N/mm2 N/mm2 mm mm mm mm mm mm mm
Operating P S Ca mt Fh D tmin tnom t t'
15.00 438.00 1.50 1.50 0.55 933.20 28.18 31.18 31.80 28.80 32.40
N/mm2 N/mm2 mm mm
d
869.60 mm
mm mm mm mm mm
Kingsnorth CCS De monstration Pro ject The information contained in this document (the Infor ma tion) is provided in good faith. E.ON UK plc, its subcontractors, subsidiaries, affiliates, e mployees, advisers, and the Depart ment of Energy and Climate Chan ge (DECC) make no representation or warranty as to the accuracy, reliability or completeness of the Infor mation and neither E.ON UK plc nor any of its subcontractors, subsidiaries, affiliates, e mployees, advisers or DECC shall have any liability whatsoever fo r any direct or indirect loss howsoe ver arising from the use of the Infor mation by any party.
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