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SUBSEA PIPELINES AND RISERS Elsevier Internet Homepage: http://www.elsevier.com Consult the Elsevier homepage for full catalogue information on all books, journals and electronic products and services. Ocean Engineering Series BOSE & BROOKE WATSON Wave Energy Conversion Practical Ship Design IS...

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SUBSEA PIPELINES AND RISERS

Elsevier Internet Homepage: http://www.elsevier.com Consult the Elsevier homepage for full catalogue information on all books, journals and electronic products and services.

Ocean Engineering Series WATSON Practical Ship Design ISBN: 008-042999-8 YOUNG Wind Generated Ocean Waves ISBN: 008-043317-0 BAI Pipelines and Risers ISBN: 008-043712-5 JENSEN Load and Global Response of Ships ISBN: 008-043953-5 TUCKER & PITT Waves in Ocean Engineering ISBN: 008-043566-1

BOSE & BROOKE Wave Energy Conversion ISBN: 008-044212-9 PILLAY & WANG Technology and Safety of Marine Systems ISBN: 008-044148-3 OCHI Hurricane-Generated Seas ISBN: 008-044312-5 KOBYLINSKI & KASTNER Stabihty and Safety of Ships Volume 1: Regulation and Operation ISBN: 008-043001-5 BELENKY & SEVASTIANOV Stability and Safety of Ships Volume 11: Risk of Capsizing ISBN: 008-044354-0

Other Titles BAI Marine Structural Design ISBN: 008-043921-7

MANSOUR & ERTEKIN Proceedings of the 15^ Ship and Offshore Structures Congress (2 volume set) ISBN:008-044076-2

CHAKRABARTI Handbook of Offshore Engineering (2 volume set) ISBN: 008-044381-8 Related Journals Free specimen copy gladly sent on request. Elsevier Ltd, The Boulevard, Langford Lane, Kidlington, Oxford, 0X5 1GB, UK Applied Ocean Research Advances in Engineering Software CAD Coastal Engineering Composite Structures Computers and Structures Construction and Building Materials Engineering Failure Analysis Engineering Fracture Mechanics

Engineering Structures Finite Elements in Analysis and Design International Journal of Solids and Structures Journal of Constructional Steel Research Marine Structures NDT & E International Ocean Engineering Structural Safety Thin-Walled Structures

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SUBSEA PIPELINES AND RISERS

YONG BAI

and

QIANG BAI

2005

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FOREWORD June 2005 Being an avid pipeline engineer for many years, it was with the keenest interest that I reviewed the contents of this new text. What I discovered was a vault of valuable and compelling information for both the seasoned pipeline engineering veteran and the newest student to the field. The subject matter is very detailed and contains the necessary depth to satisfy both the daily engineering needs as well as entry level information into developing fields. This work extends the breadth and scope of Professor Yong Bai's previous pipeline and riser text by the addition of many new subjects and fiirther depth within principal design topics. The pipeline and riser design, system reliability and flow assurance information that has been collected and developed within this book saves engineers countless hours of acquiring and compiling technical papers and specifications. And in the fast paced offshore pipeline engineering business, time like reserves is continually in short supply. The offshore industry is moving forward to grasp new technology at a quickened pace due to the growing global demand for hydrocarbon energy sources and the tight project budget requirements. The rapid pace requires new personnel to gain insight into difficult issues in a reduced timeframe. A text such as this has intrinsic value because engineers and support personnel can understand the complex issues faster and more thoroughly in order to assist the project teams in a more productive entry capacity. The text naturally assists seasoned engineers in catching up on an issue or two that may have been developing while they were absorbed in more traditional design projects through the years. New pipeline and riser technologies are being required because the new energy sources are being found in deeper water depths and in more hostile environments. Project design requirements frequently include hurricanes or typhoons, earthquakes, subsea mudslides, natural seabed erosion, liquefaction and soils transport by currents plus the industry wide goal to maintain control over our natural recourses and prevent any damage to the environment. Tsunamis are now added to this exhaustive list, highlighted by this year's major disaster. In areas like the Gulf of Mexico, routine water depths for pipeline designs are now 3,000 feet, pipelines are already installed beyond 7,000 feet and projects are encroaching on 9,000 feet depth. Deep water takes on an entirely new meaning every few years. It is likely a surprise to the students and young pipeline engineers that so much of this industry is still being redefined and reformulated due to ever evolving challenges. To accomplish a successful pipeline and riser design with high reliability, when faced with many difficult factors, engineering issues must be correctly and accurately addressed. This text yields a roadmap not only for the pipeline engineer but also the project managers, estimators and regulatory personnel hoping to gain an appreciation of the overall issues and directed approaches to pipeline and riser design solutions.

VI

Many of us who have worked within the subsea pipeUne and riser business are in the field because it has remained continuously challenging for decades. As many complex problems are carefully delineated and solved, more economical field development scenarios evolve which generate the need for yet newer solutions presenting technical gaps to be filled by the engineering community. This book is a wonderful text for the uninitiated student in the offshore adventure of subsea pipelines and risers filled with all the severe weather and complex soils conditions. Containing decades of expert information and insight into this most challenging environmental arena, many years of 'on the job' experience can be gained by simply reading this text. The information compiled and presented in this text by Professor Yong Bai and his brother Dr. Qiang Bai will certainly be a valuable reference for many years to come.

Richard D. Haun, PE Sr. Vice President OPE Inc.

FOREWORD to "Pipeliners and Risers" Book June 2000 This new book provides the reader with a scope and depth of detail related to the design of offshore pipelines and risers, probably not seen before in a textbook format. With the benefit of nearly 20 years of experience, Professor Yong Bai has been able to assimilate the essence of the applied mechanics aspects of offshore pipeline system design in a form of value to students and designers alike. The text is well supported by a considerable body of reference material to which Professor Yong Bai himself has made a substantial contribution over his career. I have been in the field of pipeline engineering for the best part of 25 years and in that time have seen the processes involved becoming better and better understood. This book further adds to that understanding. Marine pipelines for the transportation of oil and gas have become a safe and reliable part of the expanding infrastructure put in place for the development of the valuable resources below the world's sea and oceans. The design of these pipelines is a relatively young technology and involves a relatively small body of specialist engineers and researchers worldwide. In the early 1980's when Professor Yong Bai began his career in pipelines, the technology was very different than it is today, being adapted from other branches of hydrodynamics, mechanical and marine engineering using code definitions and safety factors proven in other applications but not specific to the complex hydrodynamic-structure-seabed interactions seen in the behaviour of what is outwardly a simple tubular lying on or slightly below the seabed. Those designs worked then and many of the systems installed, including major oil and gas trunklines installed in the hostile waters of the North Sea, remain in safe service today. What has happened in the intervening period is that pipeline design processes have matured and have been adapted and evolved to be fit for purpose for today's more cost effective pipelines; and will continue to evolve for future application in the inevitable move into deeper waters and more hostile environments. An aspect of the marine pipeline industry, rarely understood by those engineers working in land based design and construction, is the more critical need for a 'right first time' approach in light of the expense and complexity of the materials and the installation facilities involved, and the inability to simply 'go back and fix it' after the fact when your pipeline is sitting in water depths well beyond diver depth and only accessible by robotic systems. Money spent on good engineering up front is money well spent indeed and again a specific fit for purpose modem approach is central to the best in class engineering practice requisite for this right first time philosophy. Professor Yong Bai has made important contributions to this coming of age of our industry and the benefit of his work and knowledge is available to those who read and use this book. It is well recognised that the natural gas resources in the world's ocean are gaining increasing importance as an energy source to help fuel world economic growth in the established and emerging economies alike. Pipelines carry a special role in the development and production of gas reserves since, at this point in time, they provide one of the most reliable means of transportation given that fewer options are available than for the movement of hydrocarbon liquids. Add to this the growing need to provide major transportation infrastructure between

Vlll

gas producing regions and countries wishing to import gas, and future oil transmission systems, then the requirement for new offshore pipeHnes appears to be set for several years to come. Even today, plans for pipeline transportation infrastructure are in development for regions with more hostile environments and deeper waters than would have been thought achievable even ten yeas ago. The challenges are out there and the industry needs a continuous influx of young pipeline engineers ready to meet those challenges. Professor Yong Bai has given us, in this volume, an excellent source of up to date practices and knowledge to help equip those who wish to be part of the exciting future advances to come in our industry.

Dr Phillip W J Raven Group Managing Director J P Kenny Group of Companies

PREFACE June 2005 It has been over five years since the senior author's "Pipelines and Risers" book appeared and more than seven years since the text was written. At the time, advanced pipeline engineering, riser engineering and flow assurance were evolving rapidly as disciplines but were also approaching a degree of maturity. Perhaps it is not surprising, then, that rather little of this book now seems out-dated. The aim of this book is to cover the theory and applications of subsea field development, from front end engineering development (FEED), detail design and installation, to testing, inspection and monitoring. In response to a significant development in analysis, design, testing, inspection and monitoring, riser related chapters have been significantly expanded. Methods for riser design and integrity management have been addressed in detail. A chapter has been devoted to each type of the riser systems such as steel catenary risers (SCR), top tensioned risers (TTR), drilling risers, flexible risers, hybrid risers and umbilicals. Flow assurance has become a crucially important discipline for technical feasibility and cost effectiveness of deepwater field development. It may also govern the system selection of pipelines and risers. Hence, new chapters have been added to this edition including: subsea system engineering, hydraulics, heat transfer and thermal insulation, hydrate, wax and asphaltenes, and corrosion prevention. In preparing this book, we are grateful to Richard Haun (Senior VP of OPE Inc.) for his encouragement. Yong is indebted to his younger colleagues Johann Melillo and Xiaolin Zhang for their assistance with the new chapters on flexible risers and corrosion control respectively. Qiang would like to express his gratitude to his friends. Dr. Ian Roberts, Manager of Multiphase Services, Scandpower Petroleum Technology Inc.; Dr. Jie Lu, Technip Offshore Inc.; and Johnny C. Wu, Manatee Inc. for reviewing the flow assurance part; Ms. Helen Gao for designing the book cover. Special thanks to our wives, Hua Peng and Kumiko Okutani, for their understanding and support.

Yong Bai, Prof., Ph.D., P.E. President, Grenland Advanced Engineering Inc. (GAE) Professor, Harbin Engineering University

Qiang Bai, Ph.D., P.E. Leader - Development and Technical Group OPE Inc.

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TABLE OF CONTENTS

Foreword Foreword to "Pipelines and Risers" Book Preface

v vii ix

PART I: Mechanical Design Chapter 1 Introduction 1.1 Introduction 1.2 Design Stages and Process 1.2.1 Design Stages 1.2.2 Design Process 1.3 Design Through Analysis (DTA) 1.4 Pipeline Design Analysis 1.4.1 General 1.4.2 Pipeline Stress Checks 1.4.3 Span Analysis 1.4.4 On-bottom Stability Analysis 1.4.5 Expansion Analysis 1.4.6 Buckling Analysis 1.4.7 Pipeline Installation 1.5 Pipeline Simulator 1.6 References Chapter 2 Wall-thickness and Material Grade Selection 2.1 Introduction 2.1.1 General 2.1.2 Pipeline Design Codes 2.2 Material Grade Selection 2.2.1 General Principle 2.2.2 Fabrication, Installation and Operating Cost Considerations 2.2.3 Material Grade Optimization 2.3 Pressure Containment (hoop stress) Design 2.3.1 General 2.3.2 Hoop Stress Criterion of DNV (2000) 2.3.3 Hoop Stress Criterion of ABS (2000) 2.3.4 API RPlll 1(1998) 2.4 Equivalent Stress Criterion 2.5 Hydrostatic Collapse 2.6 Wall Thickness and Length Design for Buckle Arrestors 2.7 Buckle Arrestor Spacing Design 2.8 References Chapter 3 Buckling/Collapse of Deepwater Metallic Pipes 3.1 Introduction 3.2 Pipe Capacity under Single Load 3.2.1 General 3.2.2 External Pressure 3.2.3 Bending Moment Capacity 3.2.4 Pure Bending 3.2.5 Pure Internal Pressure 3.2.6 Pure Tension 3.2.7 Pure Compression 3.3 Pipe Capacity under Couple Load 3.3.1 Combined Pressure and Axial Force 3.3.2 Combined External Pressure and Bending

3 3 3 3 6 9 11 11 11 13 14 17 17 19 21 24 25 25 25 25 26 26 27 28 28 28 29 30 31 33 34 36 37 39 41 41 42 42 43 46 48 48 48 48 49 49 50

xii 3.4 Pipes under Pressure Axial Force and Bending 3.4.1 Case 1 - Corroded Area in Compression 3.4.2 The Location of the Fully Plastic Neutral Axis 3.4.3 The Bending Moment 3.5 Finite Element Model 3.5.1 General 3.5.2 Analytical Solution versus Finite Element Results 3.5.3 Capacity of Pipes Subjected to Single Loads 3.5.4 Capacity of Pipes Subjected to Combined Loads 3.6 References Chapter 4 Limit-state based Strength Design 4.1 Introduction 4.2 Out of Roundness Serviceability Limit 4.3 Bursting 4.3.1 Hoop Stress vs. Equivalent Stress Criteria 4.3.2 Bursting Strength Criteria for Pipeline 4.4 Local Buckling/Collapse 4.5 Fracture 4.5.1 PD6493 Assessment 4.5.2 Plastic Collapse Assessment 4.6 Fatigue 4.6.1 General 4.6.2 Fatigue Assessment Based on S-N Curves 4.6.3 Fatigue Assessment Based on Ae-N Curves 4.7 Ratcheting 4.8 Dynamic Strength Criteria 4.9 Accumulated Plastic Strain 4.10 Strain Concentration at Field Joints Due to Coatings 4.11 References

Contents 51 52 53 54 58 58 59 59 61 65 67 67 68 69 69 69 70 74 74 75 77 77 77 78 78 79 79 80 80

PART II; Pipeline Design Chapter 5 Soil and Pipe Interaction 5.1 Introduction 5.2 Pipe Penetration in Soil 5.2.1 Verley and Lund Method 5.2.2 Classical Method 5.2.3 Buoyancy Method 5.3 Modeling Friction and Breakout Forces 5.3.1 Anisotropic Friction 5.3.2 Breakout Force 5.4 References Chapter 6 Hydrodynamics around Pipes 6.1 Wave Simulators 6.2 Choice of Wave Theory 6.3 Mathematical Formulations Used in the Wave Simulators 6.3.1 General 6.3.2 2D Regular Long-crested Waves 6.3.3 2D Random Long-crested Waves 6.4 Steady Currents 6.5 Hydrodynamic Forces 6.5.1 Hydrodynamic Drag and Inertia Forces 6.5.2 Hydrodynamic Lift Forces 6.6 References Chapter 7 Finite Element Analysis o...