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IORS 2013 CONFERENCE

20TH ANNUAL
INDIA OIL & GAS REVIEW SUMMARY & INTERNATIONAL
EXHIBITION

STATE OF THE ART


PIPELAY ANALYSIS
Paper presented by: In association with:

Herman Perera Tarun Rewari


ZEE Engineering Sdn Aryatech Marine &
Bhd Offshore Services Pt Ltd
INTRODUCTION
Demand for Submarine Pipelines are increasing, due to
Increase in Energy requirements for domestic use and industrialization
resulting in;
* New Lines
* Rehabilitation / Replacement of existing lines
* Marginal field development
INTRODUCTION (cont.)
Transport lines (larger diameter and longer)
Standard DLB needs to be used
In-field lines and marginal field development (smaller diameter, shorter)
Non traditional methods need to be considered
* Surface tow (Rentis)
* On/Off bottom tow
* Variance of above
For both cases Installation is a major cost driver
INTRODUCTION (cont.)
Installation costs depend on;
Offshore spread
Methodology adopted
Optimization of Installation costs
Reduction of facilities
* Tensioner
* Wincher, davits etc.
Enables companies to have larger contractor base for competitive
bidding
Enables contracts saving of cost by using optimum facilities such as
reduction in tension.
OBJECTIVE OF PAPER
- To present a software package verified by
Model test
Field data
- Software package presented, OrcaFlex
- Computer Simulation depends on Methodology
Static
Dynamic
Pseda- Dynamic
- OrcaFlex carries out large deflection, non-linear time domain analysis
BACKGROUND
Over 25 years experience in submarine pipeline
design
Completed nearly 250 pipelines
Has developed pipeline installation software
Has used a number of industry-approved pipeline
installation software packages
- Ansys - Pipeline
- Marcs - OrcaFlex
- Sesam - Offpipe
We are not condemning or criticizing any software,
merely sharing our experience.
This presentation is based on our personal views
PIPELAY ANALYSIS
A Case Study
Labuan Pipeline (Malaysia)
Submarine pipeline from mainland to Labuan island to supply fresh water.
EPCC Contractor
Kencana/Lleighton Joint Venture (KLJV)
Line Description
26 inch diameter, approx. length 23.0km
Wall thickness 9.5mm
Steel API 5L x 52
Weight Coating
Concrete density of 2.4MT/m3
Varying thickness of 125mm to 75mm
Reinforcement 32nos 8mm steel rods will 8mm rings at 80mm CRS.
Concrete cast in moulds and compacted
Water depths 26m to 1.0m
PIPELAY ANALYSIS (cont.)
A Case Study
Project was interesting as a number of lay methods were used
Installation Methods
Traditional S lay
Surface Tow (Rentis)
Shore Pull
Mid-point tie-in
Riser stack-in
- For all the methods single program OrcaFlex was used.
Single data file
QA/QC made easy.
PIPELAY ANALYSIS (cont.)
A Case Study
- FAILURE

The pipelay operation was attempted by a contractor


and abandoned due to buckling at each joint.
As the supply of water to Labuan (a tourist destination)
was vital the project became a political issue.

- SUCCESS
The second attempt by (KLJV)

Tight Schedule
Closely monitored by Ministry and Third Party
Consultants
Was successfully concluded
PIPELAY ANALYSIS (cont.)
A Case Study
- PRELIMINARY ACTION
Pipeline was sandblasted for slippage at tensioner
Establish pipeline stiffness
* Large diameter, thin walled line with large concrete weight
* Lessons learned from earlier failure
Pipeline stiffness
* Consultant was of the opinion that the stiffness of the full
composite section should be considered.
* Preliminary analysis showed the full composite section stiffness was
note practical.
* ZEE proposed to use ASME paper recommendations for pipeline
stiffness.
PIPELAY ANALYSIS (cont.)
A Case Study
- The stiffness related to the pipeline are:

Source Stiffness (mm4) % of Bare Pipe

Bare Pipe 1.029E + 09 100.00

Full Composite 4.318E + 09 419.631

ASME Paper 1.520E + 09 147.716


PIPELAY ANALYSIS (cont.)
A Case Study
PRELIMINARY ACTION
- Analysis options:
* Stiffness of bare pipe + weight of concrete coating
* Stiffness of Composite Section + weight of concrete coating
* Stiffness as per ASME Paper + weight of concrete coating

- Preliminary Analysis
* Option 1: Touch down point close stresses very large
* Option 2: Touchdown point very far. Lessen Bending Moments, Large Tension
* Option 3: Acceptable results (our opinion)

- Action Adopted
* The effective stiffness was critical
* Decided to carry out model test for verification
MODEL TEST
Theoretical
Test model was set up as recommended in the ASME paper.
Note that the centre of model is in bending with minimal shear
(similar to actual pipeline behaviour)
PIPELAY ANALYSIS (cont.)
A Case Study
- MODEL TEST
* Full scale Model Test carried out
* Two pipeline joints with 125m,
concrete coat thickness were
field- welded
* 2 equal loads were applied
simultaneously
* Strain gauge incorporated at
center of model (field joint)
* Strain measurements were
recorded at each weight
increment
* Test was carried out to collapse
PIPELAY ANALYSIS (cont.)
A Case Study
- MODEL TEST

COMPUTER MODEL OF PIPELINE FOR STIFFNESS EVALUATION

* Physical measurements same as per actual test.


* Stiffness as per ASME paper was adopted.
* Finite Element model was segmented as per stiffness variations.
* Load increments and steps were identical to the actual test.
PIPELAY ANALYSIS (cont.)
A Case Study
- MODEL TEST
- Results (Model Test) &
Computer Simulation
* Strains vs Stiffness graph
* Very close match
* Observations
Initial stiffness of composite
section solely to self weight
As the load increased gradual
debonding of reinforced bars
and cracking of concrete
resulting in reduction of
stiffness.
At collapse the effective
stiffness was close to that of
bare pipe.
PIPELAY ANALYSIS (cont.)
A Case Study
- MODEL TEST
* STIFFNESS AT PIPELAY

* Stiffness is proportional to the bend Radius.


* For absolute accuracy the pipelay computer model should be incorporated with
varying stiffness along the line.
* This will result in a very complex F.E model requiring long computer time for
simulation/results.
* It was decided to adopt a single pipeline stiffness.
PIPELAY ANALYSIS (cont.)
A Case Study
- MODEL TEST
RECOMMENDED PIPELINE STIFFNESS
* As per DnV (1981) the criteria
set for pipelay at sag bend is 85%
SMYS.
* It was decided to adopt stiffness
value at maximum bending range
just before the cracking of the
weight coat.
* The stiffness value is approximately
equal to 145% of bare pipe
* The stiffness is as per ASME paper
recommendation
PRELIMINARY ANALYSIS

Two analyses were carried out to check


Accuracy
Simulation Time
FE MODELS
PIPELAY ANALYSIS (cont.)
A Case Study
PRELIMINARY ANALYSIS
For both cases standard pipelay analysis was carried out the following
were taken into consideration:
* Physical properties of bare pipe
* Weight of concrete coating
* Buoyancy
* Hydrodynamic properties

Full dynamic simulations were carried out with:


* Tension of 750km
* Maximum water depth
* Waves and current heading 0.0 deg
* Buoyancy bags not considered.
PIPELAY ANALYSIS (cont.)
A Case Study
- PRELIMINARY ANALYSIS
COMPARISON OF RESULTS
* Detailed simulation gave least stresses in the
pipeline system spiking at field joint locations.
This is realistic.
* Standard simulation produced higher stress
values but with a smoother curve.
* Detailed simulation took 600% of computer time
of standard simulation.
* Considering 8 stimulations for each water
depth, and actual time taken for each simulation,
it was decided to adopt the standard model for
study.
* This will give conservative results.
Analysis Max OB Max SB Touch down
Stress Stress Point (m)
(MPa) (MPa)

Standard 695.4 453.2 238.5


Detailed 412.0 399.6 172.5
PIPELAY ANALYSIS (cont.)
A Case Study
- COMPUTER SIMULATION

* Coupled time domain dynamic simulation was carried out along the pipeline route considering:
Water depth
Weight coat thickness
* The pipeline system was over-stressed both in over and sagbend locations.
* Buoyancy system needed to be incorporated.
* 2 tan buoyancy bags were used.
* 8-directional analysis were carried out for each location.
* Typical buoyancy system.
PIPELAY ANALYSIS (cont.)
A Case Study
- COMPARISON OF RESULTS
* Analysis vs Field measurements
* Field measurements only carried out for:
Water depth
Touchdown point
PIPELAY ANALYSIS (cont.)
A Case Study
COMPARISON OF RESULTS
Water Depth Touch down Tensioner Stress
(meter) (meter) (MT) % SYMS
KP
Field Field Field
Analysis Analysis Analysis Overbend Sagbend
Measurement Measurement Measurement

46 18.64 15.6 188.7 194 60 55 61 62


45 18.64 17.7 188.7 230 60 65 67 89
44 24.14 19.2 177.5 - 207 191 80 78 77 84
43 24.14 20.2 177.5 - 207 183 80 80 77 84
42 24.14 20.6 177.5 - 207 187 80 80 77 84
41 24.14 20.4 177.5 - 207 176 80 80 77 84
40 24.14 20.2 177.5 - 207 183.7 80 80 77 84
39 24.14 18.2 177.5 - 207 187 80 80 77 84
38 24.14 18.5 177.5 - 207 176 80 75 77 84
37 24.14 17.9 177.5 - 207 181.2 80 75 77 84
36 24.14 17.3 177.5 - 207 205 80 77 77 84
PIPELAY ANALYSIS (cont.)
A Case Study
- COMPARISON OF RESULTS
- OBSERVATIONS
Deviations of results within +/- 10%.
Close match except at kp 45 (possibly field measurement error)
Deviations possibly due to
* Variance in water depths
* Variance in tensioner
* Non-consideration of waves and currents for field measurements

CONCLUSIONS
Orcaflex program results closer to
Model Test
Field Measurements
ADVANTAGES OF USING ORCAFLEX

Many Advantages
- Limited time to go through

Main Advantage
- Continuous Simulation
- Speed of vessel
- Optimization of forces on jacket/ dead Anchor
ORCAFLEX SIMULATIONS

Installation Bowline Installation Bowline Davit Lift Davit Lift Stress


Stress Profile Profile

Laydown Laydown Stress


Profile
RAPID RESPONSE

SRI LANKA CPC MUTHURAJAWELA PROJECT


Shore to SPM, through Reef
Pipelay delay
Commencement of Monsoon
Waves 4-5 meter height, designed for max 2m
Pipeline buckling at each joint
Field measurement were sent to office
Within 2 days accurate models were compiled & solution given
Pipeline successfully laid.

Worst Case Solution


INNOVATIVE ENGINEERING
- RENTIS LINE

Pipeline Bundle 8 concrete coated + 4 Towed 65 Miles and Installed between


Fabricated onshore 2 Platform
INNOVATIVE ENGINEERING (cont.)
- EUROSPIRAL PIPELAY

Spiral Pipelay

Stress Profile
FUN ORCAFLEX DEMO

Boy Scout
FUN ORCAFLEX DEMO

Trampoline
FUN ORCAFLEX DEMO

Surfing Dog
FUN ORCAFLEX DEMO

Tire
THANK YOU

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