144-111-pi-cal-028_r1

Project No : 040176

PIPING FLEXIBILITY ANALYSIS

Client : Petro Canada

Project : De Ruyter Production Platform

Location : P11-b

Document number: 144-111-PI-CAL-028 Rev. no : R1 Page : 1 of 12


PIPING SYSTEMS

SK-028

PREPARED FOR

By:Iv-Oil & Gas b.v

Rev. Description Date By Checked Appr’d by

R1 For DNV Comments / Approval 12-08-2005 G.F. Costoiu R. Tjin M. van Neck

Project No : 040176




Location : P11-b


Rev. Description Date By Checked Appr’d by

R1 For DNV Comments / Approval 12-08-2005 G.F. Costoiu R. Tjin M. van Neck

Project No : 040176




Location : P11-b


TABLE OF CONTENTS Page

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

2. SYSTEM DESIGN.......................................................................................................................................... 42.1 LINE DATA........................................................................................................................................... 42.2 CII CALCULATIONS............................................................................................................................ 42.3 DESIGN LOAD CASES........................................................................................................................ 52.4 ALLOWABLE STRESSES...................................................................................................................62.5 BLAST CALCULATIONS..................................................................................................................... 62.6 PIPE SUPPORTS................................................................................................................................ 72.7 FLANGE CONNECTIONS...................................................................................................................72.8 NOZZLE LOADS.................................................................................................................................. 7

3. STRESS ANALYSIS...................................................................................................................................... 83.1 COMPUTER MODEL........................................................................................................................... 8

4. ANALYSIS RESULTS................................................................................................................................... 9

4. ANALYSIS RESULTS................................................................................................................................. 104.1 STRESSES........................................................................................................................................ 104.2 FLANGES.......................................................................................................................................... 114.3 NOZZLE LOADS................................................................................................................................ 11

APPENDICES

APPENDIX 1 STRESS SKETCHES

APPENDIX 2 PIPE SUPPORT DETAILED DRAWINGS

APPENDIX 3 CONSTRUCTION ISOMETRICS

APPENDIX 4 MISCELLANEOUS CALCULATIONS

APPENDIX 5 CAESAR II PRINTOUT

APPENDIX 6 VESSEL INFORMATION

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Location : P11-b

Document number: 144-111-PI-CAL-028 Rev. no : R1 Page : 4 of 12 1. INTRODUCTION

1.1 SCOPE OF WORK

The purpose of this report is to demonstrate that piping systems SK-028, part of De Ruyter topside piping, has inherent flexibility to accommodate displacements due to design conditions, without imposing any excessive loads on pipe supports and equipment nozzles. Furthermore the piping stress level has to satisfy the designated code.

1.2 APPLICABLE CODES

The governing code for piping design is:

ASME B31.3 Process Piping

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

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

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

ASME B16.5 Pipe Flanges and Flanged Fittings

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

1.3 REFERENCE DOCUMENTS

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

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

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

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

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

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

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Document number: 144-111-PI-CAL-028 Rev. no : R1 Page : 5 of 12 2. SYSTEM DESIGN

2.1 LINE DATA

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

Item/ Line No.

Pipe

Cla

ss

Cor

rosi

on

Allo

wan

ce

Des

ign

Pres

sure

Hyd

rote

st P

ress

ure

Max

imum

Des

ign

Tem

pera

ture

Min

imum

Des

ign

Tem

pera

ture

Ope

ratin

g Te

mp.

Med

ium

Den

sity

Flan

ge R

atin

g

Drawing Number

- mm barg barg °C °C °C Kg/m3 # -

8”-MG-200-002-B43-V B43 0 25 37.5 60 -25 50 10 300 200002-0501

8”-MG-310-003-B43-V B43 0 25 37.5 60 -25 50 10 300 310003-0501

8”-MG-200-012-B42-V B42 3 25 37.5 75 -25 60 10 300 200012-0501

8”-BD-410-009-A41-V A41 3 15 22.5 100 -11 60 10 150 410009-0501

6”-MG-310-004-B41-V B41 3 46 69 85 -20 66 10 300310004-0501/

0601

4”-MG-310-048-B41-V B41 3 46 69 85 -20 66 10 300 310046-0601

4”-BD-410-027-A41-V A41 3 15 22.5 100 -11 90 10 150410027-0601/

0301

3”/ 6”/ 8”-MG-310-053-B41-V

B41 3 46 69 85 -20 67 10 300310053-0501/ 0601/ 0801/

0802

3”/ 6”/ 8”-MG-310-016-B41-V

B41 3 46 69 85 -20 67 10 300310016-0601/

0801/ 0802

3”-MG-310-060-C41-V C41 3 60 90 85 -20 67 10 600 310060-0801

3”-HG-310-008-C43-V C43 0 60 90 60 -20 40 10 600310008-0501/

0301

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

2.2 CII CALCULATIONS

The following CII calculations have been performed:

SK-028A-R2 : Design conditions.

SK-028B-R2 : Blast loads applied between the weather deck and intermediate deck.

SK-028B1-R2 : Blast loads applied below intermediate deck.

SK-028B2-R2 : Blast loads applied above weather deck.

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2.3 DESIGN LOAD CASES

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

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

(P1) Pressure load, due to design pressure.

(P2) Pressure load, due to operating pressure.

(T1) Thermal load due to maximum design temperature.

(T2) Thermal load due to minimum design temperature.

(T3) Thermal load due to maximum operating temperature.

(D1) Nodal displacements at maximum design temperature, used at termination points N510, 1010, 3570 and 3730.

(D2) Nodal displacements at minimum design temperature, used as indicated above

(D3) Nodal displacements at maximum operating temperature, used as indicated above

(H) Hanger load.

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

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2.4 ALLOWABLE STRESSES

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

Material Max temp [ºC ]

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

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

A312 TP316 60 517 207 190.5 137.9 207 183

A333 Gr. 6 100 414 241 215137.9 207 183

Sustained Stress range Occasional

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

2.5 BLAST CALCULATIONS

The blast critical piping has been identified as per doc. no 144-002-HE-TNS-0007. These lines are:

8"-MG-200-002-B43; 6"/8”-MG-200-012-B42;

8"-BD-410-009-A41 to HP blowdown system (cont in sys SK-035); 8"-MG-200-003-B43 up to 310-ESV-101; 4"-BD-410-027-A41 from 300-BSV-177 to HP blowdown header.

In order to demonstrate the integrity of 8"-MG-200-003-B43, the following connecting lines are also considered critical (although not mentioned in document 144-002-HE-TNS-0007).

6"-MG-310-004-B41 up to 300-ESV-179; 6"-MG-310-016-B41 up to 310-ESV-201; 3"-MG-310-060-C41 up to the first ball valve.

Three calculations are made for blast. In calculation SK-028B the blast loads are applied to the entire piping between weather deck at EL +35000 and intermediate deck at El +26000. Then, in calculation SK-028B1 the blast loads are applied to the entire piping below intermediate deck at El +26000. And finally, in calculation SK-028B2 the blast loads are applied to the entire piping above weather deck at EL +35000.

Blast Load: 20 KN/m2

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

In case of calc. SK-028B2, where the blast loads are applied above the weather deck, a shape factor of 0.7 has been used.

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

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The blast loads are generated using CII wind modeler (see figure 2.5.2). The loads are applied in four (4) directions as described in section 2.3, above.

Blast load cases used for calculation are listed in figure 2.5.1. Definition of loads is as per paragraph 2.3 with exception of (D4) which represents the deflections at pipe supports and (WIN1…4) which represents the blast loads.

All supports part of the above mentioned critical lines are designed for blast loads. Further more one or two supports (depending on the actual configuration), downstream the brake, are designed for blast loads. Refer to the stress sketches attached in Appendix 1 of this report.

For blast calculations all stress intensification factors are considered equal to 1. However for simplification, in the computer models, the stress intensification factors are left as required by the design code.

2.6 PIPE SUPPORTS

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

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

2.7 FLANGE CONNECTIONS

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

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

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

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

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

2.8 NOZZLE LOADS

External loads acting on pressure vessel nozzles are compared against the allowable load sheet, doc number 144-000-ME-SPE-0004.

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Document number: 144-111-PI-CAL-028 Rev. no : R1 Page : 9 of 12 3. STRESS ANALYSIS

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

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

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

Notes

Supports at node number 165, 405 and 470 are supported from the platform at vessel 200-VS-01. Each support has been connected to the platform through a CNODE. The platform has been included in the computer model as rigid element between nodes 30 and 38, using the vessel drawings attached in Appendix 6. Refer to the sheet 1 of the stress sketches.

System Overlap

The piping indicated in stress sketch sheet 20 and 21 is part of calculation SK-029. This has been included in the computer model SK-028 as piping overlap.

The effects of the connecting piping at the termination point node 510 (sheet 4), have been accounted for by using forced nodal movements derived from node 1160, system SK-035. Refer to the table below.

Case Dx Dy Dz Rx Ry Rz

Max design temp. (D1) -0.01 3.24 0.11 0.011 0.003 0.053

Min design temp. (D2) 0.03 -0.54 -1.14 -0.001 -0.003 0.001

Max operating temp. (D3) -0.36 2.27 0.37 0.007 0.004 0.003

Translations are indicated in [mm] and rotations in [deg] for all tables.

The effects of the connecting piping at the termination point node 1010 (sheet 9), have been accounted for by using forced nodal movements derived from node 210, system SK-026. Refer to the table below.

Case Dx Dy Dz Rx Ry Rz

Max design temp. (D1) 15.56 0.00 0.00 -0.059 -0.002 0.000

Min design temp. (D2) -8.48 0.00 0.00 0.010 -0.001 -0.002

Max operating temp. (D3) 3.16 0.00 0.00 -0.033 0.000 -0.001

The effects of the connecting, overlap piping at the termination point node 3570 (sheet 20), and node 3730 (sheet 21) have been accounted for by using forced nodal rotations derived from node 4110 and 2100, system SK-029. Refer to the table below.

Node 3570 (4110 – SK029) Node 3730 (2110 – SK029)

Case Rx Ry Rz Rx Ry Rz

Max design temp. (D1) 0.033 0.033 0.000 0.003 -0.013 0.054

Min design temp. (D2) -0.011 -0.002 0.003 -0.012 0.000 0.000

Max operating temp. (D3) 0.025 0.023 -0.006 -0.001 -0.002 0.003

The pipe routing of this system is shown on the next page:

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Termination point

at Node 510

601-XY-01

Termination point at

Node 1010 (HP header

blow down)

200-VS-01

310-VN-01B

310-VN-01A

300-XY-01

Overlap - sht 20 / point 3570

Overlap - sht 21 / point 3730

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Location : P11-b

Document number: 144-111-PI-CAL-028 Rev. no : R1 Page : 11 of 12 4. ANALYSIS RESULTS

4.1 STRESSES

The maximum calculated code stresses are summarized below and compared against B31.3 code allowable values. For blast case the calculation method set in document no144-002-PI-SPE-0007 was used. The calculated 3D stress intensities are compared with yield at operating temperature multiplied by 4/.

All stresses are found to be within the allowable limits.

Table 4.1.1 Maximum Sustained Stress (SK-028A-R2)

Case No. Node MaterialCode Stress

N/mm²

Allowable Stress

N/mm²

Ratio

5 1120 A333 Gr. 6 77.0 137.9 0.55

Table 4.1.2 Maximum Stress Range (SK-028A-R2)


N/mm²

Allowable Stress

N/mm²

Ratio

17 170 A312 TP316 153.5 207 0.74

Table 4.1.3 Maximum Occasional Stress – Wind effects (SK-028A-R2)


N/mm²

Allowable Stress

N/mm²

Ratio

20 1120 A333 Gr. 6 80.5 183 0.43

Table 4.1.4 3D Stresses – Blast effects (SK-028B-R2)

Case No. Node Material3D Stress

N/mm²

Allowable Stress

N/mm²

Ratio

10 510 A312 TP316 116.7 (1) 242.5 0.48

Note: (1) The listed value is divided by the SIF (3.619) found at node 510.

Table 4.1.5 3D Stresses – Blast effects (SK-028B1-R2 / SK-028B2-R2)

Case No. Node Material3D Stress

N/mm²

Allowable Stress

N/mm²

Ratio

9 960 A333 Gr. 6 243.4 274 0.89

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4.2 FLANGES

The integrity of the ASME B16.5 flanges, under the maximum external loads, has been checked as outlined in section 2.7. The external loads are found to be acceptable. Detailed flange calculations and the summary have been included in Appendix 4 where required.

4.3 NOZZLE LOADS

Pressure Vessels

The maximum external nozzle loads are found within the allowable values (see tables below).

Note: Forces in [N] and moments in [Nm]

Table 4.3.1 Vessel 200-VS- 01 / N2

Design Case

Size Calc. No. Node No. Fx Fy Fz Mx My Mz

10”-300# SK-028A-R2 60 2300 3630 6350 6750 5100 1520

Allowable values 8600 8500 8600 7000 13000 6000

Blast Case


10”-300# SK-028A-R2 60 3460 3470 11250 11540 8235 3580

Allowable values (x 2) 17200 17000 17200 14000 26000 12000

Table 4.3.2 Vessel 310-VN- 01A / N1

Design Case


6”-300# SK-028A-R2 1660 3180 3360 1610 1485 515 1445


Table 4.3.3 Vessel 310-VN- 01B / N1

Design Case


6”-300# SK-028A-R2 6660 1120 2705 1870 2055 1140 1655


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Package Piping

The maximum external loads, at tie-in points are tabulated below and compared with allowable loads for heat exchangers and vessels, doc number 144-000-ME-SPE-0004.

Table 4.3.4 Package 300-XY- 01 / TP-05

Design Case


4”-300# SK-028A-R2 1100 3635 1) 6640 1) 540 2045 365 1050


Note: 1. The calculated forces do not act on a nozzle/ shell connection. These forces are acting at the location of the pipe support provided by the vendor at TP-05. Since the stresses in the pipe are well within the code allowable and the flange loads are found acceptable it is concluded that external loads as listed in table 4.3.4 are acceptable.

Table 4.3.5 Package 901-XY- 01 / TP-13

Design Case


3”-600# SK-028A-R2 3210 560 395 370 110 200 50


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Project title : De Ruyter Production Platform

Location : P11-b


Document number : 144-111-PI-CAL-028 Rev. no : R1

APPENDIX 1

STRESS SKETCHES

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APPENDIX 2

PIPE SUPPORT DETAILED DRAWINGS

Hold for node: 150; 165; 2220; 230; 470; 495610; 630; 640; 645; 680; 682; 770; 825; 930; 1130; 1235;1430; 1470; 1496; 1498; 1502;1504; 1530; 3580; 1315; 61756350; 6305; 6450; 6470; 65006502; 6503; 6505; 8580; 3100; 3110.

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APPENDIX 3

CONSTRUCTION ISOMETRICS

Hold for: 410014-0501; 310053-0801/ 0802; 310016-0801/ 0802310060-0801

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APPENDIX 4

MISCELLANEOUS CALCULATIONS

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APPENDIX 5

CAESAR II PRINTOUT

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APPENDIX 6

VESSEL INFORMATION

144-111-pi-cal-028_r1

Documents

piping design

design conditions

process piping

blast design strategy

stress analysis

piping stress level

pipe flanges

design load cases