Engineering Services for Off Plot Delivery

Contract (ODC) - North Oman

Stress Analysis Report.

WBS No. : C.OM.OGF.DF.11.003.S0GLD

MMC Project No. 292003QA07

Revision - 01

February 2012

Attila Dagan & Seeh AI Sarya LLC

MoU MacDonald
 MoU MacDonald

Engineering Services for ff Plot

Delivery Contract (ODC) - North
Oman

Stress Analysis Report for 20" SOGL Loop line from

Barik ta BVS-08.

Document Number: SHGOO-14-104321-LA-0580-30001-0001

Contract Number: C-311162

MMC Project Number: 292003 QA07

Revision No: 01

February 2012

Attila Dagan & Seeh AI Sarya LLC

HalaI Complex,
"B" Building,
P.O.BOX 689,
P.C. -131,
AI Hamriya
Oman
T +968 24560627

Mott MacDonald, PO Box 587, AI Barami Building, Wadi Kabir. Ruwi, 112, Oman
T +968 2485 2000 F +968 2481 5850, www.mottmac.com
 ~
Engineering Services for Off Plot Deiivery Contract (ODC) - North Oman

Mott MacDonald

Issue and revision re

Revision Date Originator Approver Description

(~
OILLY
GIRISH RAMESH NANOHAKUMAR
01 11/02/2012 NARKHEOE Issued for Detail Design
(ONK)
(GRN)
(TA~

This document is issued for the party which commissioned it We accept no responsibility for the consequences of this
document being relied upon by any other party, or being used
and for specific purposes connected with the above-captioned
for any other purpose, or containing any error or omission
project only. It should not be relied upon by any other party Dr
which is due to an error or omission in data supplied to us by
used for any other purpose. other parties

This document contains confidential information and proprietary

intelJectual property. It should not be shown to other parties
without consent from us and from the party which
commissioned il.

Mott MacDonald . PO Box 587 , AI Barami Building , Wadi Kabir, Ruwi, 112. Oman
T +968 24852000 F +9682481 5850. www.mottmac.com
 Mou MacDonald

Content
Chapter TitRe Page

1. Introduction 2
1.1 Project Background 2
1.2 Document Purpose 2
1.3 Abbreviations 2

2. Reference Documents 3
2.1 Standards and Specifications 3

3. Objectives of Stress Analysis 4

4. Design Data 5

5. Stress Analysis Methodology 6

6. Load Cases 11

7. Sei smic Analysis 12

8. Wind Analysis 13

9. Remarks & Assumptions 14

10. Stress Analysis Results 15

11. Conclusion 16
AppendixA Stress Sketches 17
Appendix B. Stress Analysis Input & Output 18
Appendix C. Attachments 19

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1. Introduction
1.1 Project Background

The South Oman Gas Une (SOGL) system transports gas for POO operations in Central and
South Oman. Gas is transported fram the Saih Nihayda area to places as far south as Marmul.
The gas transported via the (SOGL) is mainly used for power generation. Amount of gas are used
for station purging and blanketing gas. The current SOGL is formed by three pipeline segments
located between Saih Nihayda, Sahmah, Hubara and Marmul. The growth of power demand in
Central and South Oman requires new power plants and hence more gas. Based on May 2010
3
PB 11 data, POO gas consumption south of Saih Nihayda will increase fram 1.8-2.0 million m /day
3
to more than 4.0 million m /day by 2014. The SOGL system is unable to cope with this increase in
f10w and will run out of capacity by early 2013.

The objective of this project is to build a 20" gas pipeline fram the KP24.5 point in the SR CPP
(Barik) to BVS-08. Pipeline shall transport f1uids between Barik to BVS-08. This 20" pipeline shall
include pigging facility on each end.

1.2 Document Purpose

The main objective of this document is to define the findings of the stresses & thermal loads
developed on the 20" SOGL loop line.
The Stresses & Thermal loads developed due to temperature, internai pressure, routing and
external loads are analysed by using CAESAR-II (PC based pipe stress analysis software
program) Version 5.10.
The piping network has been modelled as two separate systems consisting of Pig Launcher and
Pig Receiver respectively with buried portions applicable as per layout plan.

1.3 Abbreviations

API American Petroleum Institute.

cs Carbon Steel.

ISO International Organization for Standardization.

MMC MoU MacDonald LLC

SP POO Specification

POO Petroleum Development Oman LLC

ADS Attila Dogan & Seeh AI Sarya LLC

KP Kilometre Point

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2. Reference Documents

2.1 Standards and Specifications

Shell Group Standards

DEP 31,38,01, 15-Gen Pipe Material Class-61440 Rev,E

International standards (Latest)

ASME B 31,3 Process Piping

ASME B 31,8 Gas Transmission and Distribution Piping System,

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3. Objectives of Stress Analysis

The main objectives of stress analysis and this report are:

.. To model the piping configuration matching with the actual conditions to extent possible including
the soit effect for the buried portion using the buried pipe modeller of CAESAR-II Version. 5.10.

" To analyze the induced stresses in the system due to temperature, soit friction and sustained loads
like pressure and weight.

.. To interpret the results with the requirements of ASME 831.3 & ASME 831.8 and good engineering
practice.

" Ta identify the high stressed sections and take required engineering measures wherever the
stresses are exceeding the code limits.

" Ta verify the loads at critical support points (su ch as line stop and guide) and use the loading data
for support design.

.. Ta minimize induced nozzle loads Pig Launcher and Pig Receiver nozzles and to submit the nozzle
loading data ta vendor for qualification.

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4. Design Data

• Temperature of 82°C and -10°C are shutdown temperatures and hence atmospheric pressure has
been included along with in stress analysis. These parameters are used in load case 2 & 4.

• Based on Basis of Design Report the operating temperature for the pipeline system is 50°C. The
same has been used in stress analysis input as T2.

• Ambient temperature considered is 21 ° C.

3
• Density for Dry gas has been assumed as 300 Kg/m .

• The effect of friction has been calculated based on steel to soil friction factor of 0.45 for buried
section and a friction factor of 0.3 has been used for steel to steel.

.. Soil data: ln the absence of soil investigation report, a conservative dense sandy material
assumed for ail stress systems as per the table mentioned below:

Soil properties used for underground piping

Friction coefficient (Optional if Su entered) 0.45
Soil density (required) Kg 1 cu m) 1800
Buried depth of top of pipe, mm 1546
Friction angle (Sand =27-45, Slit = 23-35, Clay = 0) deg 30
Undrained shear strength (Clay) Su. N/Sq mm)
Overburden compaction multiplier (> 0) 8
Yield displacement factor (>0) 0.015
Thermal expansion coefficient xE-6 (LlLldeg C) 11.2131
Temperature change, install operation (deg C) 29

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5. Stress Analysis Methodology

Stress analysis includes modelling & analysis of 20" Loop pipeline. The total system has been
divided in two parts as follows. The report for both systems is submitted in this report.

Al Pig Launcher System:-

20" pipeline staring from pig launcher has been modelled including 12" bypass line going to Tie-in
Point T-01 of BVS-2. Buried portion has been modelled upto sufficient length considering virtual
anchor for pipeline.

B) Pig Receiver System:-

20" pipeline on receiver portion is modelled upto pig receiver including 12" bypass line going to
Tie-in T-02 of BVS-08. Buried portion has been mode lied upto sufficient length considering virtual
anchor for pipeline.

Based on the stress analysis performed the following stresses are verified with respect to the
requirements given in ASME B31.3/ B31.8

ASME B31.3

The ASME pressure piping code B31.3 recognizes that stress due to thermal expansion tends to
diminish with time as a result of local yielding or creep. This reduction of stress will appear as a
stress of opposite sign in the cold condition. Cold springing is similar, and although hot stresses
tend to diminish with time, the sum of hot and cold stresses for any one cycle will remain
practically constant. This sum is called the stress range, and the code for pressure piping defines
this allowable expansion stress range established for thermal expansion in terms of hot and cold S
values as:

Where, Sa = allowable expansion stress range

Sc = allowable stress for cold condition
Sh = allowable stress for hot condition
F = stress range reduction factor for the cyclic condition.

The stress due to thermal expansion, which must not exceed the allowable expansion range, is
called expansion stress and is defined as:

Where, Se = computed expansion stress

=
Sb bending stress
=
St torsional stress

The sum of the longitudinal stresses due to pressure, weight and other sustained external
loadings shall not exceed Sh. If the longitudinal stresses due to sustained loadings are less than Sh,
the code permits the unused portion to be applied to extend the stress range available for
expansion effects. Therefore the code, in effect, permits a total equal to 1.25(Sc+ Sh) for thermal
expansion stress combined with stresses from other sustained loadings.

The stress analysis results were used to check the loads acting on the proposed line stops
and guides to ensure that they are within the practicallimits.

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The displacement values of the critical points were verified from the stress analysis to
ensure that the proposed pipeline configuration remains stable in the design and operating
conditions.

ASME 831.8

Restrained pipe

a) The longitudinal stress due to internai pressure in restrained pipe is

Where SH is the hoop stress.

b) The longitudinal stress due to internai pressure in unrestrained pipe is

Where SH is the hoop stress.

c) The longitudinal stress due to thermal expansion in restrained pipe is

ST = Ea(T1-T2)

Where
=
E the elastic modulus, at the ambient temperature
=
Ti the pipe temperature at the time of installation, tie-in, or burial.
=
T2 the warmest or coldest pipe operating temperature.
=
a the coefficient of thermal expansion.

d) The normal bending stress in straight pipe or large-radius bends due to weight or other
external loads is

SB= M/Z

Where
M = the bending moment across the pipe cross section.
Z = the pipe section modulus.

e) The nominal bending stress in fitting and components due to weight or other external load is

Where MR is the resultant intensified moment across the fitting or component. The
Resultant moment shall be calculated as

MR = [(0.75 ii Mi)2 + (0.75 io Mo)2 + Mt2]1/2

Where
Mi = in-plane bending moment.
=
Mt torsional moment.
Mo = out-of-plane bending moment.
ii = in-plane stress intensification factor.
io = out-of-plane stress intensification factor.
The product 0.75i ;:: 0.1

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f) The stress due to axial loading other than thermal expansion and pressure is

Sx = RIA

where
=
A pipe cross-section area.
R = external force axial component

Summation of longitudinal stress in restrained pipe

The net longitudinal stresses in restrained pipe are

=
SL Sp + ST + Sx + SB
Note that SL, ST, Sx, or SB can have negative values.
The maximum permitted valve of 1 SL 1 is 0.9 ST, where S is the specified minimum yield
strength, psi

Temp OF
Temp. Derating factor, T
:5
250 1.00
300 0.967
350 0.933
400 0.900
450 0.867

Combined Stress for Restrained Pipe

The combined biaxial stress state of the pipeline in the operating mode is evaluated using
The calculation in either (1) or (2) below:
1 SH - Sd or
2 2
[ SL -SL SH + SH ]1/2
The maximum permitted value for the combined biaxial stress is kST
Where
S is the Specified minimum yield strength
T is the temperature derating factor and k is defined as below
(a) For loads of long duration, the value of k shall not exceed 0.90
(b) For occasional non-periodic load of short duration, the value of k shaH not exceed 1.0

The biaxial stress evaluation described above applies only to straight sections of pipe

Summation of Longitudinal Stresses in Unrestrained Pipe

(a) The net longitudinal stress in unrestrained pipe is

(b) The maximum permitted longitudinal stress in unrestrained pipe is SL :5 0.75ST, where S
is the specified minimum yield strength.

ln absence of the soil data the stress analysis of the underground pipeline is solely based on the
procedure given in CAESAR Il manual which refers to the idea presented by L.C. Peng in his
paper entitled "Stress Analysis Method for underground pipelines," published in Pipeline Industry
otherwise soil model should be prepared. Soil supports shall be modelled as bi-linear springs
having an initial stiffness, an ultimate load & yield stiffness.

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Soil has got different stiffness in different directions based on which reaction is offered by the soil
to the pipe movement. The maximum soil forces because of soil stiffness & associated
displacements necessary to develop these forces are computed using the equations given below:

VERTICAL UPLlFT:

Puu = Nqv * V * H * 0

Where:
Puu = Ultimate vertical uplift resistance of the buried pipeline
=
Nqv Vertical uplift factor for sand (function of <1:> )
V =Unit weight of the sand backfill
H = Oepth from ground surface to "spring Une" of buried pipeline
o = Outside diameter of the Pipeline
The displacement corresponding to Vertical uplift, Yuu is given as
Y uu = 0.015H for loose sands
=
0.01 OH for dense sands

VERTICAL BEARING

PUB=Nq (C+0/2) * V * 0 + N * V * 0 2 /2 ............. (For sand)

y
Where:
Nq =Bearing capacity factor (function of <1:»
V =Unit weight of the sand backfill
C =Oepth from Ground surface to top of buried pipeline
o = Outside diameter of the Pipeline
Ny =Bearing capacity factor (function of <1:»

The displacement corresponding to Vertical bearing, Y UB is given as

=
Y UB 0.0200 for loose sands
= 0.0050 for dense sands

TRANSVERSE LATERAL

=
PUL Nqh * V * H * 0 .................................. (For sand)
Where:
PUL = Ultimate transverse Lateral resistance
Inch = Lateral Bearing capacity factor (function of <1:»
V = Unit weight of the sand backfill
H = Oepth fram ground surface to "spring Une" of buried pipeline
=
o Outside diameter of the Pipeline
The displacement, Y UL , required to mobilize the ultimate transverse lateral soil resistance is
related to the soil density & burial depth from ground surface.

Y UL =0.020H for loose sands

=0.015H for dense sands
LONGITUDINAL AXIAL

PUA =
J..l (2 VOc + W p)
Where:
PUA = Ultimate longitudinal axial resistance for buried pipeline
=
J..l Co-efficient of friction between pipe and soil
V = Unit weight of the sand backfill
=
o Outside diameter of the Pipeline

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C = Depth from Ground surface to top of buried pipeline
W p = Weight of pipe steel and contents

YUA = 0.2" for loose sands

= 0.1" for dense sands

The stress analysis results were used to check the loads acting on the proposed line stops and
guides to ensure that they are within the practical limits.

The stress analysÎs was performed to protect the above ground stations from stresses and loads
developed due to thermal expansion along the pipeline.

The displacement values of the critical points were verified from the stress analysÎs to ensure that
the proposed pipeline and related on-plot piping configuration remains stable in the design and
operating conditions.

The stress analysis results were used to check the loads acting on the proposed line stops
and guides to ensure that they are within the practicallimits.

The displacement values of the critical points were verified from the stress analysis to
ensure that the proposed pipeline configuration remains stable in the design and operating
conditions.
CAESAR Il Ver. 5.10 calculates the stress, displacement and load conditions for the design.

The analysis is calculated for 3 cases:

Case 1: Hydro case

Case 2: Sustained Case

Case 3: Operating cases

Shutdown with black bulb tempo
Max. operating tempo & pressure.
Shutdown with min. design tempo

The CAESAR Input & Output reports for each case are atlached in Appendix B.

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6. Load Cases
The pipeline system is analyzed for various load cases listed below, in accordance with
the Pipeline Design Code ASME B31.3 / B31.8. Typical load cases listed below are
followed in ail stress systems.

W+HP : - Hydra Test Case

W+T1+Pi :- Shutdown case with Black Bulb tempo
W+T2+P2 :-Operating case with Max. Operating tempo & Pressure.
W+T3+P1 :- Shutdown case with Min. Design Temp.
W+Pi :- Sustained case
W+P2 :-Sustained case with Max. Operating pressure.
L2-L5 :-Expansion case with black bulb tempo
L3-L6 :-Expansion case with Max. Operating tempo
L4-L5 :-Expansion case with Min. Design Temp.

Legends

W Weight of the Pipeline

Pi Shutdown (Atmospheric) Pressure of the Pipeline
P2 Max. Operating Pressure of the Pipeline
Ti Black bulb (shutdown) temperature of the Pipeline
T2 Max. Operating Temperature of the Pipeline
T3 Min. Design Temp. of pipeline
HP Hydra test Pressure

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7. Seismic Analysis
Seismic Analysis has been ignored in this stress analysis.

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8. Wind Analysis
.. The basic wind speed is based on a 3 second gust speed occurring at 1Dm above
ground .
.. Wind analysis has been ignored for the pipeline section as the height to width ratio
of pipeline equipment is around 2.0 while UBC-97 code requirement specifies a ratio
greater than 5.0 or presence of structures sensitive of wind-excited oscillations.

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9. Remarks & Assumptions

e Unless otherwise mentioned, rigid weights of ail Flanges, Valves with bolts weights
are taken either from CAESAR database or from Standard Pipe Data.
e As per the plant north configuration, "-X "is considered as "North" for modelling
and analysis.
e No settlement has been considered for stress analysis at pipe support or at
equipment support.
e Existing 16" buried line beyond Tie-in point T-01 is mode lied to consider effect of
existing buried pipeline on new pipeline and vice-versa.
It Nozzle neck thickness for pig launcher and pig receiver are assumed same as
barrel thickness of 12.5 mm in absence of vendor General arrangement drawing.
It Nozzle loads for pig launcher and Pig Receiver are attached in Appendix-C These
loads need to submit to vendor for approval.

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10. Stress Analysis Results

CI The stress analysis has been carried out using CAESAR-II Version 5.10.
CI The detailed output reports are given as Appendix B of this report.
e The principal output parameters are summarized in this section for ready
reference.
CI The maximum stress ratios of each model are:

Table: Stress ratios for each stress systems:

Stress ratios
Max.Operating
Stress System. Sustained Remarks
condition
Value % Node Value % Node
Pig Launcher 92.8 3801 45.3 5060 Acceptable
Pig Receiver 80.6 7148 80.5 7148 Acceptable

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11. Conclusion
The results, summarized in section 10 of this report, demonstrate:
'" The thermal and sustained stresses are within code allowable limits as defined by ASME
B31.3/B31.8.
'" The nozzle loads on nozzles of Pig Launcher and Pig Receiver needs to be submitted to
vendor for approval.
e The loads acting on the proposed line stops and guides are acceptable.
e The above ground pipeline configuration is stable for the design conditions.

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Appendix A. Stress Sketches

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