KILO-W-CAL-0403 Pipeline Expansion Calculation 8” KC-KA 3 Phase Rev. a (15!07!13)

Document Number

Project Title KILO Field Further Development Project

KILO-W-CAL-0403 Validation 2 Years Expired Date 9-Oct-2015

Author’s Organization PT. DWE - Engineering

Expansion Analysis for 8” KC-KA 3 Phase Pipeline

Approval Sheet Name

Title

Hartono

Project Manager

Anik Artha

Project Lead

Andreas Deny

Engineering Lead

Date

Signature

Revision Status Rev

Issue Date

By

Chk

App

A 0

15-Jul-2013 09-Oct-2013

ALIT ALIT

LUTHFI LUTHFI

SUTRISNO SUTRISNO

Issue Purpose Issued For Review Issued For Approval

Owner Signature

PT. PHE ONWJ

Expansion Analysis for 8” KC-KA 3 Phase Pipeline

Review & Endorsement Records This document has no review and endorsement records

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Expansion Analysis for 8” KC-KA 3 Phase Pipeline

Revision Log Register Revisions had been performed on following pages: Page 6 8 9

Date 9-Oct-2013 9-Oct-2013 9-Oct-2013

Revision Update Objective as per client comment Update Analysis Carried Out as per Client Comment Add Section 4.4 Temperature Profile

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Expansion Analysis for 8” KC-KA 3 Phase Pipeline

Table of Contents Review & Endorsement Records 1 Revision Log Register 2 Table of Contents 3 1. Introduction 4 1.1. General4 1.2. Objective 6 1.3. Scope 6 1.4. Associated Documents 6 1.5. Pipeline Reference 6 1.6. Abbreviation 7 2. References 7 2.1. International Code & Standards 7 2.2. Company Document 7 2.3. Project Document 7 3. Conclusions and Recommendations 8 3.1. Analysis Carried Out 8 3.2. Summary 8 3.3. Recommendation 8 4. Pipeline Design Parameter 9 4.1. Pipeline design life 9 4.2. Pressure and Temperature 9 4.3. Pipeline and Riser Mechanical Properties 4.4. Subsea Pipeline External Coating System 4.5. Concrete Coating Properties 11 4.6. Corrosion Allowance 11 4.7. Environmental Data 11 4.7.1. Water Depth 11 4.7.2. Tidal Range 12 4.7.3. Seawater Properties 12 4.7.4. Soil Parameters12 5. Method of Analysis 13 5.1. Pipeline Strain 13 5.2. Frictional Resistance 13 5.3. Anchor Point 14 5.4. Pipeline Expansion 14 6. Results and Conclusions 16 6.1. Analysis Carried Out 16 6.1. Pipeline Expansion Results 16

9 10

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1.

Expansion Analysis for 8” KC-KA 3 Phase Pipeline

Introduction

1.1. General KILO Area consists of four producing platforms which are KA, KB, KC and JJA. Based on 2012 reserves report, this field is still potential and will add more production to Offshore North West Java Operation. Currently only KA platform active using in-situ gas lift source, but this gas source has limited to continuous production in KA platform need more gas source from another field. KC platform was shut down in November 2002 due to 3-phase pipeline KC-KA leak and KB platform was shut down in June 2006 due to 3 phase pipeline KB-KPRO leak. KC platform was producing about 500 BOPD and 1 MMSCFD before shut in 11 years ago (2002). This was happened because of pipeline leak between KC and KA platform. The same problem also occurred in KB platform in 2006. A leaking in a sub-sea pipeline between KB and KPRO platform requires the platform to be shut in. The production lost due to KB shut in is about 350 BOPD and 1.7 MMSCFD. KA platform was reactivated and online in September 2012 with initial rate 700 BOPD and 1.5 MMSCFD. This study will give assurance reserve in KILO field to support in reactivate KB and KC platforms.

Figure 1: Simplified last KILO Area Operation Total recoverable reserves in KILO field is 12.2 MMBO and 47.5 BSCF with consist of base production 2.4 MMBO and 9.3 BSCF, and from POFD can add reserves 9.8 MMBO and 38.2 BSCF. Maintaining base production to recover this reserves (3.4 MMBO and 8.8 BSCF), wellwork (4.3 MMBO and 10.2 BSCF), and infill well (4.5 MMBO and 28.6 BSCF). Total peak production from this field 5903 BOPD and 17.49 MMSCFD will be achieved in October 2016. The plan to reactivate KILO platform divided two phase, first phase was completed at September 2012 and success reactivated KA, KPRO and KCOM platforms, and second phase will be reactivated KB and KC platforms at Q4 2015.

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Expansion Analysis for 8” KC-KA 3 Phase Pipeline

Based on Appraise and Select Study, fluid from JJA, KB and KC will be separated in KCOM production separator V-1000, while fluid from KA wells will flow to KPRO production separator CV-2. Gas out from KPRO production separator comingles with gas out KCOM production separator and will be sent to B2C platform as sales gas using new MGL KCOM-B2C. While liquid out KPRO production separator comingles with liquid out KCOM production separator and will be sent to NGLB using existing 8” MGL KCOM-NGLB as export liquid. The gas lift for KILO wells will be supplied from B1C platform using new gas lift pipeline B1C-KCOM and in-situ gas lift.

Figure 2: Process Schematic KILO Field Further Development Project Pipeline route in KILO Field Further Development Project is presented below.

Figure 3: Pipeline Route in KILO Field Further Development Project

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Expansion Analysis for 8” KC-KA 3 Phase Pipeline

1.2. Objective This document contains study and calculation of expansion analysis stability for subsea pipeline of KILO Field Development which consist of 8” KC-KA 3 Phase pipeline. The result of this analysis determines the pipeline expansion and anchor length of pipeline end at pipeline of KC Platform to KA Platform. The expansion analysis is divided into two cases as follows:  Hydrotest condition considering new pipe, water content, hydrotest pressure and sea floor & content (sea water) temperature during hydrotest condition and,  Operating condition considering 100% corroded product content, maximum operating pressure and sea floor & design temperature during operating condition.

1.3. Scope The scope of this report is 8” KC-KA pipeline for both pipeline zone 1 and pipeline zone 2 excluding expansion spools and riser.

1.4. Associated Documents Following table listed all documents that referred by and related to this report Table 1 - Related Documents Document Title

Document Number KILO-G-DBS-0001

Project Design Basis

KILO-G-PHI-0001

Project Design Philosophy

KILO-W-CAL-0401

Wall Thickness Analysis for 8” KC-KA 3 Phase Pipeline

KILO-W-CAL-0402

On-Bottom Analysis for 8” KC-KA 3 Phase Pipeline

1.5. Pipeline Reference The Submarine pipeline and Riser that is required to be installed as part of the KILO Field Further Development Project described in table below. Table 2 - Pipeline Reference Pipeline

Pipeline OD (mm)

Origin

Termination

Service

8” dia. Pipeline

219

KC

KA

3 Phase

Platform Center Position

Table 3 - Key Coordinates Location Latitude

Longitude

KA Platform

6° 1' 48.77" S

107° 40' 48.70" E

KC Platform

6° 2' 06.20" S

107° 41' 08.92" E

Table 4 - Platform Water Depth Parameter Platform Center Position Water Depth (m) KA Platform

28.96

KC Platform

29.87

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Expansion Analysis for 8” KC-KA 3 Phase Pipeline

1.6. Abbreviation API ASME CA ERW HAT MSL NPS PHE ONWJ SMLS SMTS SMYS 2.

American Petroleum Institute American Society of Mechanical Engineer Corrosion Allowance Electric Resistance Welding Highest Astronomical Tide Mean Sea Level Nominal Pipe Size Pertamina Hulu Energi Offshore North West Java Seamless Specified Maximum Tensile Strength Specified Minimum Yield Strength.

References

2.1. International Code & Standards The latest versions of the listed documents shall be used in the design, installation, and operation of the proposed for Subsea Pipeline. This list is not exhaustive and will be updated during subsequent phases of the project. 1. API 5L

Specification for Line pipe

2. DNV OS F101

Submarine Pipeline Systems

2.2. Company Document 1. PHEONWJ-W-SPE-0005

Specification for Line Pipe

2. PHEONWJ-W-SPE-0006

Specification for Pipeline Corrosion Protection Coating

2.3. Project Document 1. KILO-G-DBS-0001

Project Design Basis

2. KILO-O-SDY-0002

Flow Assurance and Hydraulic Study of Pipeline

3. KILO-W-CAL-0401

Wall Thickness Analysis for 8” KC-KA 3 Phase Pipeline

4. KILO-W-CAL-0402

On-Bottom Analysis for 8” KC-KA 3 Phase Pipeline

5. RPT/ STC0811/KCOM-BCOM/0.1

12 K-COM TO B-COM2 (MGL) Subsea Pipeline & 8-inch B-COM1 to K-COM (Gas Lift) Subsea Pipeline Proposed Pipeline Route Survey Offshore North West Java, Indonesia. PID361-14”KC-KA MOL/MOL Pipeline Asset Report

6. EGS-R014007-UNIFORM-W-PLR-0001

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3.

Expansion Analysis for 8” KC-KA 3 Phase Pipeline

Conclusions and Recommendations

3.1. Analysis Carried Out Design pressure of 950 psig and temperature profile based on Pipeline Hydraulic Steady State Simulation [Ref. 2.3. (2)] were considered for the expansion analysis at operating condition. Detail calculations are presented in Appendix A and Appendix B. For the expansion analysis, the following conditions were considered. 1. Operating Condition (corroded pipe, filled with product and 100 year return period). 2. Hydrotest Condition (new pipe, filled with sea-water and subject to hydrotest pressure and 1 year return period)

3.2. Summary The Pipeline end expansion results are summarized in Table 5. Table 5 - End Expansion Analysis Result Pipeline End Expansion (mm) Case

Anchor Length (m)

At KC (Hot End)

At KA (Cold End)

At KC (Hot End)

At KA (Cold End)

Operating Condition(1)

79

68

401

401

Hydrotest Condition

70

67

401

401

Note: 1. The result subject to changing based on temperature profile from hydraulic analysis report [Ref.2.3.(2)]

3.3. Recommendation The expansion of 8” diameter subsea pipeline at KC to KA shall be adopted for riser and spool flexibility analysis.

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4.

Expansion Analysis for 8” KC-KA 3 Phase Pipeline

Pipeline Design Parameter

The pipeline specific design data are provided in Project Design Basis. However, any specific and important design data used for expansion calculation are specified herein for easy reference.

4.1. Pipeline design life The design life for the pipeline system is 20 years.

4.2. Pressure and Temperature Service pressure and temperature of pipeline systems are presented in table below. Table 6 - Pipeline/Riser Process Data Parameters

Units

8” KC-KA 3 Phase Pipeline

Design Pressure

psig

950

Max. Operating Pressure

psig

164

psig

1330

Hydrotest Pressure Mechanical Design Temperature (Metal)

(1)

Operating Temperature Density of Content

0

F

0

F

kg/m

Service

200 109 3

37.32

-

3 Phase

Note:

1.

For non-mechanical materials (external corrosion coating), the design temperature shall be the operating temperature added by 30oC [Ref.2.1.(5)].

4.3. Pipeline and Riser Mechanical Properties The following tables are present pipeline and riser mechanical properties. Table 7 - Pipeline/Riser Mechanical Properties Parameters

Units

8” KC-KA 3 Phase Pipeline

Outer Diameter

mm

219

Wall Thickness

mm

12.7

Material

-

API 5L Grade X52MO or X52QO PSL2 CS

Seam Type

-

SMLS, SAWL or HFW

SMYS

MPa

360.0 (52.20 ksi)

SMTS

MPa

460.0 (66.70 ksi)

Young Modulus

MPa

2.07 x 105 (30022.9 ksi)

Poison Ratio

-

0.3

Density

kg/m

Coefficient of Thermal Expansion

o

/C

3

7850 1.1 x 10-5

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Expansion Analysis for 8” KC-KA 3 Phase Pipeline

4.4. Temperature Profile Data The temperature profile for operating condition is adopted from hydraulic analysis whereas temperature profile for hydrotest condition is generated by logarithmic formulae presented in Appendix A. Table 8 - Temperature Profile at Operating Condition (by hydraulic analysis) No

Temperature o

Length m

1 2 3 4 5 6 7 8 9 10

C 42.66 42.51 42.49 42.47 39.65 37.34 29.32 27.30 26.80 26.69

0 0 5 9 24 38 138 238 338 438

11 12 13 14 15 16 17 18 19

26.67 26.66 26.66 26.66 26.66 26.53 26.42 26.39 26.37

538 638 738 838 878 893 908 913 917

Remark At Launcher Point

Pipeline Start

Pipeline End

At Receiver Point

Table 9 - Temperature Profile at Hydrotest Condition (by logarithmic formulae) No 1 2 3 4 5 6 7 8 9

Temperature o

C 30.00 27.35 26.81 26.70 26.68 26.67 26.67 26.67 26.67

KP Km 0.00 0.10 0.20 0.30 0.40 0.50 0.60 0.70 0.80

Remark Pipeline Start

Pipeline End

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Expansion Analysis for 8” KC-KA 3 Phase Pipeline

4.5. Subsea Pipeline External Coating System The external anti-corrosion coating systems for subsea pipeline are presented below: Table 10 - Subsea Pipeline Coating Properties Parameters Units Asphalt Enamel Thickness Asphalt Enamel Density

Value

mm

4.0

kg/m3

1281.5

mm

150

Cut Back - Asphalt Enamel

4.6. Concrete Coating Properties The properties of concrete coating are presented below: Table 11 - Concrete Coating Properties Units

Parameters Density

kg/m

3

Value 3044

Thickness

mm

32

Cut Back

mm

300 + 10

%

2-5

Absorption

4.7. Corrosion Allowance Internal Corrosion allowance for all section pipelines and riser presented below: Table 12 - Internal Corrosion Allowance Location

Internal Corrosion Allowance (mm)

All section pipeline/Riser

3.0(1)

Note : 1. The Internal corrosion allowance was considered based general engineering data since the pipeline will be transport the sweet fluid without any H2S content.

4.8. Environmental Data 4.8.1. Water Depth The pipeline water depth data along the route are presented below.

Item

Table 13 – Water Depth Data Unit

Value

Minimum Water Depth

m

28.96

Maximum Water Depth

m

29.87

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Expansion Analysis for 8” KC-KA 3 Phase Pipeline

4.8.2. Tidal Range The tidal data along the route are presented below : Table 14 - Tidal Data Item

Units

Storm Tide (Surge)

m

Highest Astronomical Tide (HAT)

m

Return Period 1-Year

100-Year

0.152

0.244 1.158

4.8.3. Seawater Properties The seawater properties are presented below.

Parameter Density of Sea Water Sea Water Temperature Kinematics Viscosity

Table 15 - Sea Water Properties Unit kg/m o

Value

3

1025

F

80

2

1.13 x 10-5

m /s

4.8.4. Soil Parameters Based on marine survey report RPT/ STC0811/KCOM-BCOM/0.1 (Ref.2.3.6), generally the seabed top soil layer can be categorized as soft clay. Detailed of soil characteristic are presented in below table.

Parameter Soil Type

1)

Undrained Shear Strength1) Angle Friction

1)

Submerged Weight2)

Table 16 - Soil Parameters Units

Value

-

Very Soft Clay

kPa

2.0 – 5.0

Deg

0.0

kg/m3

815.7

Note: 5. Soil type based on marine survey report RPT/ STC0811/KCOM-BCOM/0.1, specific at KCOM area. 6. Submerge weight is adopted from DNV RP F105 for soil clay type.

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Expansion Analysis for 8” KC-KA 3 Phase Pipeline

5. Method of Analysis During its design life, pipeline is subjected to an increase in internal pressure and temperature from its as-installed condition. These loads cause the pipeline to expand at its free end and induce stresses and forces in the pipe wall.

5.1. Pipeline Strain Pipeline expansion is calculated by integrating the net strain along the pipeline hot and cold anchor lengths. The description of individual strain components were described in the subsequent section. Refer Figure 5 for strain components illustration. 5.2.1. End Cap Strain The end cap strain is caused by the internal pressure of the fluid in the pipeline acting at an effectively "closed" end of a pipeline, such as a bend. The strain is approximately as per following formula, this strain acts over the whole length of the pipeline

E 



2

 Pin Di  Po Do . 4 EAs

2

 ………………………………………………………………………...5.1

5.2.2. Poisson Strain The Poisson strain is a result of the action of the hoop stress, which radially expands the pipeline. According to Poisson's effect, a longitudinal strain is developed and is given by

V   .

 Pin .Di  Po .Do  2.t 2 .E

..........................................................................................................5.2

5.2.3. Temperature Strain When a pipeline is installed, its length in an unstressed condition is governed by the ambient temperature of the seawater. Any increase in this temperature will cause thermal expansion given by

 T   .T ……………………………………………………………………………………..5.3 5.2.4. Total Applied Strain The total applied strain acting along the pipeline length is the summation of the applied strains described above, i.e. εtot= εE+εν+εT………………………………………………………………………………………....5.4

5.2. Frictional Resistance Friction resistance between an object and the surface it is resting on is given by the Coulomb relationship, resulting from the normal force acting between the surfaces. For a pipeline, the fictional resistance increases linearly with distance, L, from the pipeline free end, in proportion to the cumulative pipe weight. For buried pipelines, additional resistance to movement is provided by the soil pressure acting around the pipeline, as shown in Figure 5.2.1. The frictional resistance is given by:

   .Dt2  . b .g.H b .Dt .(1  K o )  (Ws   b .g . ) 4   2

F  

……………………………………...5.5

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Expansion Analysis for 8” KC-KA 3 Phase Pipeline

The frictional strain is given by:

f 

F .L As .E ……………………………………………………………………………………5.6

ρb*g*(H *g*(Hpc-Dt/2) -Dt/2) pc

ko*ρs*g*Hpc

Dt

ρb*g*(Hpc+Dt/2) Figure 4: Frictional Forces for Buried Pipe 5.2.1. State of Strain in the Pipeline The applied strain in the pipeline is opposed by the frictional strain, giving a net strain

 net   tot   f

……………………………………………………………………………………...5.7

5.3. Anchor Point At a certain point along the pipeline, the frictional resistance strain is large enough to equal the applied strain, forming an anchor point beyond which pipeline movement is prevented. As friction is a "passive" reaction, it is only mobilized to an amount less than, or equal to, the applied strain. The location of the anchor point can be determined by equating the applied force to the frictional force, therefore

LA 

 tot . As .E F ………………………………………………………………………..……………5.8

5.4. Pipeline Expansion Once the state of strain in the pipeline is determined, the expansion at the free end can be found by integrating the strain over the anchor length. LA

L 



net ( z )

 ( tot   f ).dz ……………………………………………………………………5.9

0

 F .L L   tot .L A    2.E. As 2 A

 

 ………………………………………………………………………..5.10

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Expansion Analysis for 8” KC-KA 3 Phase Pipeline

Hot end expansion (ΔLh) is given by: Lh

Lh 



net

.dx ……………………………………………………………………………..……5.11

0

Cold end expansion (ΔLc) is given by: L

Lc 



net

.dx

L  Lc

…………………………………………………………………………….…….5.12

Figure 5: Pipeline Strain Diagram – Long Pipeline

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Expansion Analysis for 8” KC-KA 3 Phase Pipeline

6. Results and Conclusions 6.1. Analysis Carried Out 1. Two conditions were considered for end expansion analysis, i.e. maximum operating condition with 100% corroded and Hydrotest with un-corroded pipe. 2. For Hydrotest case, fluid content temperature was considered to be equal to sea water temperature and ambient temperature equal to minimum sea floor temperature of 15 oC as a conservative approach. 3. For operating case, temperature profile was considered from pipeline hydraulic calculation and ambient temperature equal to minimum sea floor temperature as a conservative approach. 4. The pipeline is assumed to be straight with no lateral or vertical curvature. Both pipeline ends are assumed to be free. The restraining effect of the risers is considered negligible. 5. Residual lay tension is neglected. 6. The pipeline is restricted by seabed soil friction only. The soil friction is assumed constant along pipeline. 7. Marine growth is neglected.

6.1. Pipeline Expansion Results Summary of results for the pipeline thermal expansion analysis for 8 inch KC-KA 3 Phase pipeline is presented Table 17. Table 17 - Summary of the Pipeline Thermal Expansion analysis for 8”KC-KA 3 Phase pipeline Temperature Expansion Anchor Length Line pipe WT (oC) (mm) (m) Case OD (mm) Inlet Outlet Ambient At KC At KA At KC At KA (mm) Operating

12.7

37.34

26.67

15.00

79

68

401

401

12.7

30.0

26.67

15.00

70

67

401

401

219 Hydrotest

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Expansion Analysis for 8” KC-KA 3 Phase Pipeline

Appendices  

Appendix – A Appendix – B

: :

8” KC to KA 3 Phase Pipeline Expansion Calculation (Hydrotest) 8” KC to KA 3 Phase Pipeline Expansion Calculation (Operation)

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Appendix A. 8” KC to KA 3 Phase Pipeline Expansion Calculation (Hydrotest)

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Appendix B. 8” KC to KA 3 Phase Pipeline Expansion Calculation (Operation)

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