Design and Installation of Marine Pipelines

384 Pages·2005·5.952 MB·English

by  Braestrup, Mikael W.(eds.)

Design and Installation
of Marine Pipelines
Mikael W. Braestrup (Editor)
Jan Bohl Andersen
Lars Wahl Andersen
Mads Bryndum
Curt John Christensen
Niels-Jørgen Rishøj Nielsen
Blackwell
Science
DAIA01 1 2/12/04, 10:36 AM
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First published 2005
Library of Congress Cataloging-in-Publication Data
Design and installation of marine pipelines / M.W. Braestrup...[et al.]. – 1st ed.
p. cm.
Includes bibliographical references and index.
ISBN 0-632-05984-2 (hardback : alk. paper)
1. Underwater pipelines. I. Bræstrup, Mikael W. II. Title.
TJ930.D378 2005
621.8’672’09162—dc22
2004017651
ISBN-10: 0-632-05984-2
ISBN-13: 978-0632-05984-3
A catalogue record for this title is available from the British Library
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Preface
The construction of marine pipelines is a relatively new field of engineering,
having developed in the course of the last five decades. Yet, with more than
100000km of subsea lines installed worldwide it must be regarded as a mature
technology, although advances continue in extending the limits as regards pipe
dimensions, pressures, flow regimes, products, installation methods, water depths
and climatic environments. It is therefore surprising that there is a shortage of
books that cover the entire process of marine pipeline design and installation,
from project planning through to system operation.
Marine pipelines are generally designed, fabricated and installed in accordance
with guidelines issued by various certifying agencies and regulatory bodies, as
well as national and international codes. Ideally, however, a code should be a
fairly slim volume, based upon functional performance criteria. The choice of
design methods and construction procedures should be left to the engineers
responsible, relying on a general consensus of good engineering practice, backed
up by shared literature and education experience. However, this is precisely the
material that is generally lacking in the marine pipeline field.
The aim of this publication is therefore to complement the existing codes and
recommendations with an engineering book, serving as a guide to the profession
with the objective of ensuring a reasonable standard of design and application.
The book is primarily aimed at engineers who are fairly new to the field of
marine pipelines, and want a comprehensive overview of the subject. The book
should also provide background reading to students on specialised offshore courses,
and to professionals in related fields. To experienced pipeline engineers it would
constitute a reference work to be consulted for fact and figures.
The origins of the work go back to 1987, when it was felt that there was a need
for a Danish national code for marine pipelines, and a code-drafting working
party was established, eventually comprising most of the authors of the present
book, chaired by the editor. The Danish marine pipeline code never materialised,
but the working party identified the need explained above, and began collating
supporting documentation, which eventually evolved into the present textbook.
The result constitutes a set of comprehensive guidelines for the design and
xii
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Preface xiii
installation of marine pipeline systems, but the authors take no responsibility for
the use of the recommendations given.
The authors acknowledge the valuable comments to the draft manuscript
offered by Robert Inglis of J P Kenny. It should be stressed, however, that the
responsibility for any errors or omissions rests with the authors alone. Finally,
the authors would like to thank Dansk Olie og Naturgas A/S (DONG A/S) for
permission to use photographs from the 1998–99 installation of the South Arne
to Nybro 24-inch Offshore Gas Pipeline.
Mikael W. Braestrup
Jan Bohl Andersen
Lars Wahl Andersen
Mads B. Bryndum
Curt J. Christensen
Niels J. Rishøj Nielsen
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About the authors
Editor
Mikael W. Braestrup, MSc, PhD
Born in 1945, Dr Braestrup obtained his PhD in structural engineering from the
Technical University of Denmark in 1970. After spending two years as a volun-
teer in charge of low-cost road construction in Peru he was engaged in structural
concrete research and teaching in Copenhagen, Denmark, and Cambridge, UK.
He joined the consulting company RAMBOLL in 1979, and worked for five
years on the design and construction of the offshore pipelines of the Danish
Natural Gas Transmission System. Subsequently he has headed the RAMBOLL
departments of Marine Pipelines and Underwater Technology, and of Knowledge
and Development.
Since 1992 Dr Braestrup has been attached to the RAMBOLL Department of
Bridges, but is also active in the field of marine pipelines. Recent assignments
include coating design for the 24″ Danish North Sea gas trunkline and the 30″
BalticPipe between Denmark and Poland, feasibility studies for a 42″ gas trans-
mission pipeline across the Baltic Sea from Russia to Germany, and secondment
to the Statoil engineering team for the export pipelines of the Kristin HP/HT
subsea development. Dr Braestrup is an active member of a number of interna-
tional associations (fib (CEB-FIP), IABSE, ACI), has served on several Danish
code committees, and is the author of a substantial number of papers and reports
on civil engineering subjects, including marine pipelines.
Co-authors
Jan Bohl Andersen, MSc, started his professional career at the RAMBOLL
pipeline department, and then spent some years as an independent consultant,
mostly in Norway. Since 1993 he has been back with RAMBOLL, specialising
in design, contracting, and project management of marine pipelines.
xiv
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About the authors xv
Lars Wahl Andersen, MSc, worked in the RAMBOLL pipeline department
until 1992, when he transferred to the Department of Risk and Reliability. His
expertise on safety and risk studies is widely applied to offshore projects, plat-
forms as well as pipelines.
Mads Bryndum, MSc, is chief engineer in the Ports and Offshore Department at
DHI Water and Environment. Mads Bryndum has a background in structural
engineering and worked for several years at C G DORIS on the design of con-
crete gravity platforms. He joined DHI in 1980 and has specialised in hydraulic
and hydrodynamic problems in relation to marine pipelines and risers.
Curt John Christensen, BSc, has been employed by FORCE Technology
(formerly the Danish Welding and Corrosion Institute) since 1976 as a corrosion
and metallurgy specialist. He started in the marine engineering sector and, from
1980, he has been deeply involved in oil and gas industry and pipeline industry
related jobs. From 1985 to 2000 he was in charge of the full scale pipeline testing
activities at FORCE Technology.
Niels-Jørgen Rishøj Nielsen, MSc, PhD, heads the Engineering and R&D
Department of NKT Flexibles I/S. Following a PhD in structural optimisation of
ship structures, he began his professional offshore career in 1984 at the Danish
Maritime Institute. He then moved to Maersk Olie og Gas A/S, working in their
pipeline department, and spent some years at the DNV Copenhagen office before
joining NKT Flexibles in 1995.
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Contents
Preface xii
About the authors xiv
Glossary and notation xvi
Chapter 1 Introduction 1
Chapter 2 Bases for design 5
2.1 Introduction 5
2.2 Basic requirements 6
2.2.1 Functional requirements 6
2.2.2 Authorities’ requirements 6
2.2.3 Environmental impact 7
2.3 Flow calculations 8
2.3.1 General 8
2.3.2 Operational parameters 9
2.3.3 Pipeline size determination 10
2.3.4 Flow simulations 10
2.4 Site investigations 13
2.4.1 General 13
2.4.2 Geophysical survey 14
2.4.3 Geotechnical survey 15
2.4.4 Soil sampling and in situ testing 16
2.4.5 Laboratory testing 17
2.5 Meteo-marine data 17
2.5.1 General 17
2.5.2 Wind, waves and current 18
2.5.3 Collection of wave data 19
2.5.4 Design parameters 20
2.6 Route selection 21
2.6.1 General 21
2.6.2 Alignment sheets 23
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iv Contents
Chapter 3 Materials 24
3.1 Introduction 24
3.2 Soil materials 25
3.2.1 General 25
3.2.2 Seabed soil classification 25
3.2.3 Backfill materials 27
3.3 Linepipe materials 27
3.3.1 General 27
3.3.2 Strength, toughness and weldability 29
3.3.3 Sour service resistance 32
3.3.4 Steel microstructure and corrosion resistance 34
3.4 Sacrificial anodes 36
3.4.1 General 36
3.4.2 Zinc alloy 36
3.4.3 Aluminium alloy 37
3.5 Pipeline component materials 37
3.5.1 General 37
3.5.2 Component materials for sour service 38
3.6 Coating and insulation materials 38
3.6.1 General 38
3.6.2 Material properties 39
Chapter 4 Loads 40
4.1 Introduction 40
4.2 Functional loads 40
4.2.1 General 40
4.2.2 Internal pressure 41
4.2.3 Pressure control systems 41
4.2.4 Temperature 45
4.3 Environmental loads 45
4.3.1 General 45
4.3.2 Hydrodynamic forces 45
4.3.3 Hydrodynamic force coefficients 49
4.4 Accidental loads 52
4.4.1 General 52
4.4.2 Dropped object loads 52
4.4.3 Trawl loads 53
4.5 Installation loads 55
Chapter 5 Risk and safety 56
5.1 Introduction 56
5.2 Safety policy and philosophy 57
5.3 Risk management 58
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Contents v
5.3.1 General 58
5.3.2 Hazard identification 60
5.4 Risk acceptance criteria 61
5.4.1 General 61
5.4.2 Cost benefit analysis 63
5.5 Risk assessment 64
5.5.1 General 64
5.5.2 Risk reducing measures 65
5.5.3 Example: Risk of anchor damage 65
5.6 Special risk aspects 70
5.6.1 Subsea isolation valves 70
5.6.2 Welded or flanged connections 71
5.6.3 Corrosion in HP/HT pipelines 71
5.7 Statistical data 72
Chapter 6 Design 73
6.1 Design conditions 73
6.1.1 Codes and standards 73
6.1.2 Serviceability limit states (SLS) 74
6.1.3 Ultimate limit states (ULS) 75
6.1.4 Partial safety coefficients 75
6.2 Wall thickness determination 76
6.2.1 General 76
6.2.2 Design methods 77
6.2.3 Location class definition 78
6.2.4 Wall thickness according to DNV OS-F101 79
6.2.5 Code comparison and national wall thickness regulations 82
6.2.6 Trawling and hydrostatic pressure 86
6.2.7 Wall thickness design example 91
6.3 Hydrodynamic stability 92
6.3.1 General 92
6.3.2 Design activities 94
6.3.3 Design conditions and requirements 100
6.3.4 Static stability design format 102
6.3.5 Dynamic stability design format 103
6.3.6 Pipe–soil interaction 103
6.4 Free span evaluation 110
6.4.1 General 110
6.4.2 Free span classification 111
6.4.3 Pipeline and free span data 112
6.4.4 Static analysis 113
6.4.5 Dynamic analysis 116
6.4.6 Fatigue analysis 117
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vi Contents
6.5 Expansion and global buckling 120
6.5.1 General 120
6.5.2 Pipeline expansion 121
6.5.3 Pipeline buckling 125
6.5.4 Upheaval buckling 126
6.6 Corrosion prevention and insulation 132
6.6.1 General 132
6.6.2 Corrosion of steel in seawater 133
6.6.3 Internal corrosion prevention 134
6.6.4 External barrier coating 137
6.6.5 Thermal insulation 138
6.7 Cathodic protection 140
6.7.1 General 140
6.7.2 Protective potential and current requirements 141
6.7.3 Hydrogen embrittlement 142
6.7.4 Sacrificial anode design 143
6.7.5 Impressed current 150
6.7.6 Electrical isolation 152
6.7.7 Stray current interference 152
6.8 Bends, components and structures 153
6.8.1 General 153
6.8.2 Fittings 153
6.8.3 Valves and other components 154
6.8.4 Structures 155
Chapter 7 Fabrication 156
7.1 Introduction 156
7.2 Linepipe production 157
7.2.1 General 157
7.2.2 Standardisation 158
7.2.3 Seamless pipe 159
7.2.4 Welded pipes 160
7.2.5 Specified properties of linepipe steels 164
7.2.6 Hot formed bends 167
7.2.7 Cladding, lining and weld-overlaying 168
7.2.8 Testing during pipe manufacture 169
7.3 Internal coating 171
7.3.1 General 171
7.3.2 Surface preparation 172
7.3.3 Fusion bonded epoxy (FBE) 173
7.3.4 Epoxy paint 173
7.3.5 Inspection and testing of epoxy paint 173
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