15050901-000-00-PI-BOD-0002_C

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PREVIOUSREVISION

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TRANSMITTAL NO .

15050901·KP T·01083

DATE

01.09.2015

APPROVALCODE

B

CONTRACT NO: I OMPANY PROJECT NO : I ALE ·N A BASIS15050901 EF/1852 · · ·

SHEETCONTRACTOR DOC . No.: I REV. I SHEET

15050901 000 00 PI 800 0002 C 1of

26

K.O .C. DOC . No. :

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PAGE ARSHEAVYOI LD EVELOPMENT PROGRAM

I~

· · · · · · · · · · · · · · · · · · · · · · · ~ --·--···-·-···-···--·-···-···------·--··· ·I

___o_n_ra_c_ N__. _1_ o_so_9_1 f_o_oc_. _No_. : 15050901-000-00- PI-BOD-0002 _REV : c 2 of 26 mpany Proj. No.: EF /1852 1

1.0

2.0

2.1

2.2

2.3

3.0

3.1

3.2

3.3

3.4

3.5

4 .0

4.1

4.2

4.3

4.44.5

4.6

4.7

4.8

4.9

4 . 10

a)

b)c)

d)

e)

f

g

4.11

4.12

4.13

4.14

4.15

4.16

PROJECT OVERVIEW

PURPOSE

ONTENTS

4

4

SCOPE ....... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

DEFINITIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

ABBREVIATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .......... . .... 5

REFERENCES . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

KOC STANDARDS . . . . . . . . . . . . . . . .. . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

OTHER COMPANYREFERENCE STANDARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

PROJECT SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

INTERNATIONALCODES 8: STANDARDS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

ORDER OF PRECEDENCE . . . . . . . . . . . . . . .. . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

CRITERIAAND METHODOLOGYFOR STRESS ANALYSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

SOFTWARE ANDVERSION . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........... 9

UNITS .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

BASIC DESIGN PARAMETERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10DESIGN LIFE.... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

INSTALLATIONTEMPERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

ANALYSIS TEMPERATURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ 10

ANALYSISPRESSURE ....... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

PIPE MATERIALAND THICKNESS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

LOADINGSFOR STRESS ANALYSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Thermal Loads at Various Operating Conditions

Sustained LoadsSeismic Loads

Wind Loads

PSV Reaction Force

Slug Force

Forces Induced by Surge Pressure

11

' 1111

12

13

13

14

FRICTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

DISPLACEMENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

GUIDES 8: AXIALSTOPS ....... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

DECOUPLING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

LOADS ON EQUIPMENTNOZZLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

FLANGE LEAKAGECHECKS. . . . . •..... .... . . . . . . . .. .. . •. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

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·· . - - - - ~ ~ C T I T ~ ~: ·

Petrofac ®A····

1

Piping Stress Analysis Design Basis

PAGE LOWER FARS HEAVY OIL DEVELOPMENT PROGRAMPHAS E - 1 60MBOPO)

Contract No. : 15050901--------- ----------- - - - - DOC . No. : 15050901-000-00-Pl-BOD-0002 REV. : C 3 of 26 Company Proj . No . : EF/1852 I

4 . 17 PIPESAG . . . . .. . . .. . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . .. . .. .. . . . . . . . . . . .. . . . . . .. . . . . . . . . . . . .. 18

4.18 ACOUSTIC INDUCEDVIBRATION FLOWINDUCEDVIBRATION . . . . . . . .. . .. .. . . . . . . . . . . 18

4.19 GLASS REINFORCED EPOXY (GRE) PIPE . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... 18

4.20 PIG TRAPS (LAUNCHER/RECEIVER). . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

4.21 DYNAMIC ANALYSIS. . . .. .. . .. . . . . . . . . .. . . . . .. .. . .. . . . . . . . .. . . . . . . . . . . . . . .. . . . . . .. ... . .. . . .. . .. 19

4.22 SPRING/STRUT SUPPORTS/SNUBBERS/SWAY BRACES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

4.23 EXPANSION JOINT, SWIVELJOINT/HOSE. .. . . . . . .. . . . . . .. .. .. .. . . . . .. .. . .. . .. . . . . . . . .. . .. . 19

4.24 STRESS AND STRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

5.0 RECORDS . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

APPENDIX-1 (STRESS ANALYSIS BASIS FOR CRITICALLINES NEAR TIE-INS). . . . . . . . . . . . . . . . . . . . . . . ... 21

APPENDIX-2 (SEISMIC G LOAD CALCULATIONAS PER UNIFORMBUILDINGCODE) . . . .. ... . . . . . . . . . 22APPENDIX-3 (METHODOLOGYFOR TRUNKLINESTRESS ANALYSIS)ERROR BOOKMARK NOTDEFINED.

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-- - -· - ~ T I T L E :--- -- - - -

PAGE LONER FARS HEAVY O IL DEVE LOPM ENT PROGRAMPHAS E -1 (60MBOP D)

Petrofac IDA Piping tress Analysis Design Basis

ontractNo.: 15 5 9 1 ~ ~ ; ~ ~~ o s o 9 o~ o o o o ~ B O D O O O Z__ 1 ; E ~~ ~ 4 of6 ~ : ~ p : ~ ~ ; ; ~ N o ~E F / ~ ~ ~ ; ~ =I

1.0 PROJECT OVERVIEW

Kuwait Oil Company (K.S.C), hereafter called COMPANY, have awarded the consortium of

Petrofac International Ltd. (Petrofac) and Consolidated Contractors Group

S.A.L(Offshore)(CCC),thereafter called CONTRACTOR, the Works comprising all things to be

done and services to be provided by CONTRACTOR including but not limited to the

engineering design, procurement of Material, expediting, shipping, placement of

Subcontracts, project management, construction, inspection, testing, pre-commissioning,

training of COMPANY personnel, commissioning, operation and maintenance during the

ramping up of production to 60 MBOPD until turnover, performance testing and all other

works to complete the Lower Fars Heavy Oil Development Program Phase-1 (60 MBOPD)

on a Lump sum Turnkey (LSTK) basis, to provide COMPANY with complete, proven and

operable facilities.

Phase-1 facilities comprises of two well blocks which shall be designed to process a nominal

60,000 BOPD of heavy oil. The field shall be developed using thermal recovery process which

shall employ Cyclic Steam Stimulation (CSS) followed by Steam Flood (SF).

The broad scope involves development of Production Support Complex (PSC), Central

Processing facility (CPF), Well Blocks 02 and 03, Infield Satellite Station (ISS), Trunk and Steam

Lines, Pipelines for Export Oil, Fuel Gas, Make Up and Disposal Water, Sub Stations, New

Storage Tanks along with Loading and Filling Manifolds and New Crude Oil Control Centre

(COCC) and Pumps in South Tank Farm (STF).

2.0 PURPOSE

The purpose of this document is to provide a basis of design for performing Piping

Flexibil ity /Stress Analysis .

2.1 ScopeThe scope of this document is to define the Design criteria and basis to be used for Piping

Flexibil ity /Stress Analysis of Metallic, Non-Metallic piping and Trunkline piping. This also

includes pipeline and Trunkline stress analysis criteria which are designed in accordance

with ASME B31. 3 code.

2. 2 Defini tions

For the purposes of this document the following definitions shall apply:

The word 'shall' indicates a mandatory requirement.

The words 'may' 'can' indicate one acceptable course of action.

The word 'should' indicates a recommended course of action.

COMPANYor CLIENT KUWAITOIL COMPANY.

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rPetrofac ®A

DOC. TITLE:

Piping Stress Analysis Design Basis

PAGE LO'NER FARS HEAVY OIL DEVELOPMENT PROGRAMPHA SE -1(60MBOPO)

···············--·-···--·--······-···---·---····-···-·············--·-·-···--·-----···---- E · ·-··---·--···--·--- ·--········--------------- _

Contract No : 15050901 DOC No : 15050901 000 00 PI BOD 0002 REV : C 5 of 26 Company Proj . No .: EF/1852·

CONTRACTOR Petrofac International Ltd, the part which carries out

all or partof

the Design, Engineering, Procurement,Construction and Commissioning of the Project.

VENDOR The party which manufactures and/or supplies the

equipment.

THIRD PARTY INSPECTOR (TPI) The Inspection agency appointed by Company orContractor

2. 3 Abbreviations

A/G Above Ground

AIV Acoustic Induced Vibration

ANSI American National Standards Institute

API American Petroleum Institute

ASME American Society of Mechanical Engineers

ASTM American Society for Testing and Materials

DLF Dynamic Load Factor

FlY Flow Induced Vibration

IFC Issued for Construction

NPSNominal Pipe Size

P ID Piping & Instrumentation Diagram

PMS Piping Material Specification

PSV Pressure Safety valve

SIF Stress Intensification Factor

TPI Third Party Inspection

U/G Under Ground

3.0 REFERENCES

3.1 KOC StandardsKOC Engineering Standards listed below will be complied with, as relevant.

Document No. Description

KOC-G-007 Basic Design Data

KOC-L-028 KOC Recommended Practice for Plant Layout

KOC-MP-010 Piping Material Classes

KOC-MP-011 (Part 1 and 2) RTRP Pipes & Fittings: Design, Materials and Installation

015-IH -1002 Pipeline Design

3.2 Other Company Reference Standards11 C8972-00-PE-SPC-0002 -R - Specification for Piping Design

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- - - - - -DOC. TITLE :

@ Piping St re Analy•i• De•ign Ba•i• rrPAGE LOWER FARS HEAVY OIL DEVELOPMENT PROGRAM

etrofac

··· ······ · · · · · · · ·· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·· r· · · · · · · · · · · · · ~ · · · · · ~ ~ E _ : ~ ~ ~ ~ ~ ~ _ : ~ }I

Contract No . : 15050901 DOC. No. : 15050901-000-00-PI-BOD-0002 REV.: C 6 of 26 Company Proj. No .: EF/1852· L I

11 C8972-00-PE-SPC-0022-RO - Specification for Allowable Nozzle Loads for Mechanical

\ Equipment11C8972-00-PE-SPC-0019-RO - Specification for Pipe Supports

3.3 Project Specifications

Project specifications cover the technical requirements specific to the project as required

by the contract.

Document No. Description

15050901-000-00-PI -BOD-0001 Specification for Piping Design

15050901-000 -00 -PI -SPC-0002 Piping Material Specifications

15050901-000-00 -PI-PSS-0001 Piping Supports Standard

15050901-000-00-PI-SPC-0001 Specification for Allowable Nozzle Loads

15050901-000-00-CI-BOD-0001 Civil and Structural Design Basis

15050901-000-00-PR-CRT-0001 Process Design Criteria Memorandum Phase-1 - IISS CPF

15050901-621-00-PR-CRT-0002 Process Design Criteria Memorandum Phase-1 -ExportFacility STF)

3.4 International Codes Standards

The following codes and standards shall apply as a minimum:

The latest edition of the codes prevailing as on July 2014 shall be applied .

API 520

API 521

API 560

API 610

API 617

API 619

API 650

API 661

API 674

API 675

Sizing , Selection and Installation of Pressure Relieving Devices in

Refineries

Pressure-relieving and Depressuring Systems - Sixth Edition

Fired Heaters for General Refinery Services

Centrifugal Pumps for Petroleum, Petrochemical and Natural Gas

Industries

Axial Centrifugal Compressors and Expander-compressors for

Petroleum , Chemical and Gas Industry Service

Rotary Type Positive Displacement Compressors for Petroleum,Petrochemical and Natural Gas Industries

Welded Tanks for Oil Storage

Air -Cooled Heat Exchangers for General Refinery Service

Positive Displacement Pumps - Reciprocating

API 676

Positive Displacement Pumps - Controlled Volume

Positive Displacement Pumps - Rotary

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· . . ·-1

etrofac

·· ···· ···· · ·- · T. · · ·· ········· ···· ·

A J:: DOC TITL

Vl u Piping Stress Analysis Design Basis

PAGE LCM ER FARS HEAVY OI L D EVE LOPMENT PROGRAMPHASE -1(60MBOPD)

- · ··· ··· · ··· ·· · · ··· ······· ········ · · ··· -···---·---···--·· ·-···--·····-· r· · · · · · ·--·----·----····----······--·-·-· ·· ··· ··· · · ··-- · · j

Contract No.: 15050901 DOC. No. : 15050901-000-00 - -BOD -0002 _REV.: C 7 of 26 Company Proj. No. : EF/1852 I

API 1102 Steel Pipelines Crossing Railroads and Highways

API TR 6AF1

ASME B16.5

ASME B16.47

ASME B31.1

ASME B31.3

ASME B31.4

ASME B31.8

ASME Sect. VIII

EJMA

Technical Report on Temperature Derating on API Flanges underCombination of Loading

Pipe Flanges and Flanged Fittings

Large Diameter Steel Flanges

Power Piping

Process Piping-2012 Edition

Pipeline Transportation Systems for Liquid Hydrocarbons andOther Liquids

Gas Transmission and Distribution Piping Systems

Boiler and Pressure Vessel Code

Expansion Joint Manufacturers Association

BS EN ISO 14692 Part 3 GRP Piping Part 3: System Design

NEMASM 23

NFPA 20

WRC Bulletin 297

I WRC537

WRC Bulletin 449

ASME SEC Ill 1

3. 5 Order of Precedence

Steam Turbines for Mechanical Drive Service

Installation of Stationary Pumps for Fire Protection

Local Stresses in Cylindrical Shells due to ExternalLoadings on Nozzles - Supplement to WRC Bulletin 107

Precision on Equations and enhanced diagrams for Local Stresses

in Spherical and Cylindrical Shell Due to External Loadings for

Implementation Of WRC Bullet in 107

Guidelines for the Design and Installation of Pump Piping Systems

Rules for Construction of Nuclear Power Plant ComponentsDivision 1 - Subsection NC Class 2 Components.

The supply of Equipment, materials, services , and documentation shall be in accordancewith the State of Kuwait and local rules and regulations and specific projectrequirements.In case of conflict on technical requirements, the following order of precedence shallapply;• Specifications

• Datasheets

• DrawingsIn case of conflict or differences in requirements of the codes and standards, the moststringent of such codes and standards as defined by Contractor/Company shall apply.

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· i······· ·········-

®AOC. TITLE:

Piping t ress Analysis Design Basis

retrofac?

:= ..";:...---=-."""=

PAGE LONER FARS HEAVY OIL DE VELOPMEN T PROGRAMP HASE - 1(60MBOPO)

·-········---······----···--·-- --·-···-···-----······---···--··-·----·········-·--·····--·-·····-·--·--·-- ···--·--···-·--·--- · · · · · · · · · ·--- ·[_ Contract No . : 15050901 DOC. No . : 15050901-000-00-PI-BOD -0002 REV. : C 8 of 26 Company Proj. No .: EF/1852 i

.

4.0 DESCRIPTION

4.1 Criteria and Methodology for Stress Analysis

Stress critical lines shall be identified as per the criteria in Table-1 below based on issued

P IDs and corresponding Process Line List .

The stress critical lines shall be grouped under different stress systems based on layout,

P ID, etc. A unique stress system number shall be assigned for each stress system.

If a stress critical line is similar or identical to a previously analyzed line, with no significant

change in dimensions process conditions, then the line shall not be stress analyzed.

Table -1 Criteria for Stress Critical Lines(Ref clause 7.3 of 11C8972-00-PE-SPC-0002-RO-

Specification for Piping Design and also refer Notes given below the table)

Nominal Pipe Size (NPS)Line size, Temperature &

Connected Equipment/ System 2 3-6 8-10 12 -18 20 & above

Lines with Design TemperatureNo Analysis required Analysis

-45 °C to 44°C requiredLines with Design Temperature more

No Analysis required Analysis requiredthan 45 °C

Lines with Design Temperature moreNo Analysis required Analysis required

than 105 °C

Lines with Design temperature more No Analysis Analysis requiredthan 160 °C required

Lines with Design temperature more Analysis requiredthan 215 °C

Lines with Design temperature less No analysis Analysis required if temperature is not due tothan -46 °C required blowdown effect)

Lines connected to Rotating or No analysis Analysis requiredReciprocating equipment. required

No analysis Analysis requiredLines connected to Boiler or Heaters required

Lines associated with safety relief No analysis Analysis requiredand/or emergency blowdown required

systems

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Connected Equipment System

Lines subjected to Slug or Surgeeffects

RTRP lines shall be checked withc \vendor recommendation

Lines subjected to significantdifferential displacements such asbut not limited to wellhead growth,tank settlement, etc.Lines subjected to cyclic loading inexcess of 7000 cycles for the systemdesign life

Firewater Piping subjected toearthquake or blast loading

2

No analysisrequired

No analysisrequired

No analysisrequired

No analysisrequired

No analysisrequired

Nominal Pipe Size NPS)

3-6 1 8-10 1 12 -18 120 above

Lines susceptible to Slug flow shall be identifiedby Process in Line List. Analysis required for all

such lines

Shall be checked with vendors recommendation

Analysis required

Analysis required

Analysis required

(i) For Piping Systems for which comprehensive analysis is not required based on above

criteria, visual review shall be done to ensure that these lines are adequately

supported as per support span in Pipe Support Standard Doc no: 15050901-000-00-PI

PSS-0001.(ii) Two-phase flow lines, i not qualified as per above criteria (Table -1 ), need not be

analyzed in Caesar-11. Proper supporting arrangement shall be provided to take care

of two-phase flow effects.

(iii) Contractor stress engineer would be reviewing before Stress Isometrics are sent to

GRE/FRP Vendor and review subsequent work by GRE/FRP vendor.

4.2 Software and Version

Stress Analysis Calculations shall be performed using CAESAR II, 2014 version 7.0

4.3 Units

5 units shall be used for Stress Analysis Calculation and for Documentation. Listed below

are some of the specific units recommended for use.

• Force: N (Newton)

• Length: mm (mill imete rs)

• Pressure: Bar ( a for absolute and g for gauge)

• Stress: N/mm 2 (Newton per mm 2

• Moment: N-m (Newton-meter)

• Temperature: ° C (degree Celsius)

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IjPetrofac

j:: .. I DOC. TITLE ,

IJl ) u Piping Stress Analysis Design Basis

IContract No. : 15050901[_________ _

• Density: Kg/ m

4.4 Basic Design Parameters

Basic parameters to be used for Stress Analysis are listed below:

4. 5 Design Life

For purposes of Piping Design, the Design Life shall be 25 years. Equivalent number of full

displacement cycles for thermal analysis shall be considered as 7000.

4.6 Installation Temperature

Below are the installation temperatures to be considered, which are based on clause 5.4 of

project site climatological data detailed in document number: KOC-G-007:

a) For Hot lines:

For lines that are normally under hot service", 7 Deg C based on daily minimum

temperature shall be considered as installation temperature. These are the lines

normally operating at or above ambient temperature, and having hot insulation or no

insulation.

b) For Cold lines:

For lines that are normally under "cold service", 46 Deg C based on daily maximum

temperature) shall be considered as installation temperature. This shall be adopted

only for those lines that are normally operating at temperature below ambient

temperature, and having cold insulation.

4. 7 Analysis Temperature

The Design temperature (Maximum/ Minimum values as per Line List) shall be used for

thermal analysis. If any upset or occasional case temperature is specified in line list, then

the same shall be used for stress qualification and maximum operating temperature shall be

used for qualifying equipment nozzle and support loads while maximum to minimumtemperature shall be used for stress range check.

In addition to the maximum/minimum design/operating temperatures, Piping shall also be

analyzed for the Normal Operating temperature. Design temperature shall be used as for

stress qualification as a stand-alone case.

For the nozzle load evaluation of rotating equipment, piping shall be considered at

normal/maximum/minimum Operating Temperatures.

For nozzle load evaluationof

static equipment piping shall be consideredat

designtemperature, normal, maximum, minimum operating temperature, max Ope+ Seismic, max

Ope+ Wind.

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~ r C T I T L · · · · · · · · · · · · · · r · t - -

IPetrofac @A I Piping Stress Analysis Design Basis i j ~ ~

IP GE I LOWER FARS HEAVY O IL DEVE LOPM ENT PROGRAM

I~

l contract No. : 15050901 ~ ~ ~ s o s 0 9 0 1 0 0 0 o o B O D { Q 0_2__ ; ~~~ ~ i t _ o ~ ~ a n y ~~L No. : EF/1852

4.8 Analysis Pressure

Line Design Pressure specified in the Line List shall be considered as the analysis pressure.4. 9 Pipe Material and Thickness

Piping Material, Thickness and Corrosion Allowance shall be as per Piping Material

Specification 15050901 -000 -00-PI-SPC-0002.

Any other parameters shall be taken from the relevant Project documents software

databases .

4.10 Loadings for Stress Analysis

The types of loads to be considered in Stress Analysis shall be as given below:

a) Thermal Loads at Various Operating Conditions

Analysis Temperature and Pressure to be used shall be as mentioned in clauses 4. 7

4.8 above.

b) Sustained Loads

Sustained loads to be considered are as given below:

• Design pressure .

• Weight of Pipe and associated componen ts such as Flanges, Valves , Strainer,Sight glass etc. mounted on the Piping System.

• Weight of Fluid /contents in the piping.

• Insulation and cladding weigh t.

• Hydro test loads, if applicable for the line.

• Snow load , if applicable.

c) Seismic Loads

Kuwait falls within seismic probability Zone 1 and generally seismic loads are notgoverning than wind induced loads except for large size pipe work. Therefore the

seismic effect is not required to be considered in the piping design. Where ever

Seismic Design is required to be carried out, equivalent Static Seismic Analysis

method in Caesar shall be used to evaluate the seismic stresses , displacements and

loads on the piping system.

The maximum Operating Temperature shall be used when analyzing for Occasional

loads. Seismic loads shall be considered as acting along the horizontal axes both in

Ve and in the -ve directions, that is, along North , South , East and West directions),

but not acting simultaneously.

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; - · - · - - - - - · - - - · · · ·· · · · · · · · · · · · · · · · · · · · . l · ·· · · · · · · · · ~ ;

1 ~ IDOC. TITLE :

lp t ~ I l l 1 Piping Stress Analysis Design Basis 11

? /~ e ro ac (j} J ~ :;::::;;:... ;:;._ =

I l ~ LOWER FARS HEAVY O IL DEVELOPMEN T PROGRAMP HASE - 1 60MBOP D)

i .

[_contract No . : 15050901 lo o c No. : 15050901-000 -00 PI -BOD 0002 J EV . : :__ 1~ ~ f o m . . : ~ ~ YProj. No. : EF/1852

Seismic loads shall be considered for Lines of 14" and higher sizes wherever wind is

not conside red for analysis.In accordance with clause 5.11.1 of document number: KOC-G-007 "Basic Design

Data" seismic condition shall be calculated as per Uniform Building Code Vol.2 with

Seismic Zone -1, Zone factor=0 .075 and Soil profile type=SD (Stiff Soil). Accordingly

the value of Seismic g load factor for input in stress calculation is calculated as 0.1 g.

This value shall be used for cases where seismic effect is applicable. The seismic g

load factor calculat ion is enclosed as Appendix-2 of this document .

d) Wind oads

Wind loads shall be considered for lines with outside diameter NPS 14 (including

insulation) above and at Elevation 10 meters above from ground level. The

maximum Operating Temperature shall be used when analyzing for Occasional loads.

Wind shape factor shall be considered as 0.7. Wind loads shall be considered as

acting along the horizontal axes (both in the +ve and in the -ve directions, that is,

along North, South , East and West directions), but not acting simultaneously.

Wind pressure for the different Elevations shall be as per the "Civil/Structural

Specification/Structural Design Basis " Document number: 15050901-000-00-CI-BOD-001. The same shall be considered for wind data input in piping analysis.

Velocity-Pressure calculation

Height Velocity Pressure for all

above theExposure

structures Velocity PressureCoefficient qz (KN/m 2

)ground for all equipmentkz for

level, zCategory c ( For use in Piping design) as qz (KN/m 2

)

(m) per ASME B31.3 )

0-4.6 0.85 1 44 1.60

6.1 0.90 1.52 1 .70

7 6 0 .94 1.59 1 .78

9.1 0.98 1.66 1.85

12.2 1.04 1.76 1 97

15.2 1.09 1.85 2.06

18 1.13 1.91 2.14

21.3 1.17 1.98 2.21

24.4 1.21 2.05 2.28

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1

.£.1

DOC. TITLE :

JPetrofac @ A . ~

1

Piping s t re s Analy•l• De•lgn •••I•

----- --

1

PAGE LONER FARS HEAVY O IL DEVELO PM ENT PROGRAM

l ontract No .._: _1s_o .s_o_9o_1 ~ ~ - SOS 9_0_1 ~ ~ P B O ~ 2- -F ~ ~ 13 of26

PHAS E - 1 60 MBOPO) ·Company Proj. No. : EF/1852

· · · · · · · · · ·

e)

Height

above the ExposureCoefficient

groundkz for

level, zCategory c

m)

27.4 1.24

30.5 1.26

36.6 1 . 31

42.7 1.36

48.8 1.39

54 .9 1.43

PSV Reaction Force

Velocity Pressure for all

structures

qz KN/m 2

For use in Piping design) as

per ASME B31.3)

2.09

2.14

2.22

2.29

2.36

2.42

Velocity Pressure

for all equipment

qz KN/m 2)

2.34

2.39

2.48

2.56

2.64

2.70

Pressure relief loads shall be calculated for both open and closed relief systems.

Manufacturers calculated relief valve loads shall be used when available. When

manufacturers loads are not available relief valve forces shall be calculated in

accordance with API RP 520 and API RP 521. Suitable bracing shall be specified,

where necessary , to absorb resulting forces in order to prevent overstressing of the

piping. Such forces shall be treated as occasional loads . A DLF Dynamic Load Factor)

of 2.0 shall be applied to the relief valve loads.

However , in the case of high reaction force values, the DLF value calculated as per

Appendix - of ASME B31.1 may be used, based on valve data i f provided by Vendor.

f Slug Force

For lines having slug flow regime, as identified by the Process group on PftiD/linelist, slug force shall be considered in the piping stress analysis. Slug force shall be

calculated as below and applied at all changes of direction.

stug = p) A) V2 [2 1 -cos 8)] 112 DLF

Where,

Fsug = Force due to slug in Newton.

p = Density of the slug in Kg/m 3,

A = Inside area of pipe cross section in m 2,

V =Velocity of moving slug in m/sec.

e =inclusion angle at elbow or change of direction

DLF = Dynamic Load Factor DLF) equal to two shall be used.

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DOC. TITLE :

Piping t ress Analysis Design Basis

PAGE LOJIIER FARS HEA VY OI L DEVELOPMENT PROGRAMPHA SE -1(60MBOPD)

1

1Petrofac @

---- ·---···-···-·----·--- ··---·-----------······--···--··- - ----- 1 _,________ ,_____ _____ __ , ___________, ___________,14 o f I

Contract No : 15050901 DOC. No. : 15050901-000 -00-PJ -BOD-0002 REV : C 26 Company Pr oj . No. : EF/185 2 IL · = 1

Generally DLF shall be equal to 2 except where the magnitude of load is high in

which case DLF shall be calculated taken from Process to calculate slug force.At a 90 ° bend (or 90 ° change in direction or at intersection),

I

x l =

F rth ogon al =(p) A) V2

) DLF(p) A) V2

) DLF

Slug properties shall be obtained from Process group.

Calculated Slug loading can be applied using the static equivalent method in Caesar

II. Particular attention shall be given to the pipe support design for these systems.

Pipe supports shall be capable of withstanding the slug load without interfering with

thermal expansion.

g) Forces Induced by Surge Pressure

The effect of surge on any line, as identified by the Process group or a specialist

agency, shall be considered in piping analysis.

However two concurrent occasional loadings need not to be considered in piping

stress analysis.

All piping components shall be suitable to the maximum surge peak pressure and

support system shall be designed to withstand unbalanced surge force.

4 . 11 Friction

Friction shall be considered at all supports. Use of PTFE slide plates at supports to reduce

fric tion shall be minimized. The friction co-efficient to be used are as follows.

Contact Surfaces Materials Co-Efficient Of Friction

Carbon Steel to Concrete 0.40

Carbon Steel to Carbon Steel 0.30

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r ® DOC. TITLE ' p;plng Stre Analy•l• De•lgn , , ·r ®IPetrofac _t ····· · ·· __________________________

1

PAGE _ _ _O _ R _A R _ _ ~ _ ; ~ ~N_T PR ~ ~ ~,

I Contract No . : 15050901 OC. No. : 15050901-000-00-PI -BOD-0002 l ; ~ :C1~ t Company Pro j . No . : EF/1852 IL_____________________________·····-·····---······---·--·--·-·········-·-·----·····-···-···--······--·--··-······ L · ······ ···--------·- · · · · · · · · · · · · · · · ·

Carbon Steel to Stainless Steel (Mirror Finished) 0.20

I & : ~ : ~ ~ : : : t : : ~ ~ :ss ~ ; ~~ : i : ~ ; E F : : i : : : ~0.15

0.10

Friction co-efficient shall be applied at guides line stop locations also to simulate the

actual effect in the system, in addition to the resting support locations. Frictionless

unrestrained movement shall be considered at hanger rod, strut supports and at spring

hanger locations (other than bottom springs).

4 12 isplacements

Thermal expansion/Nozzle displacement at Equipment shall be considered in Stress Analysis

by modeling the equipment as rigid elements, with appropriate fixed points, and with the

application of temperature profile applicable to the Equipment. Local nozzle flexibility as

per WRC 537 WRC 297 API 650 may be included, wherever it becomes necessary in order

to avoid over-conservative design.

Significant differential settlement value shall be considered in the analysis.

For tanks, long term (post hydro test) settlement value as provided by Civil shall be

considered in the analysis.

Vessel skirt/saddle expansion shall be ignored , since the expansion from these items is

insignificant as co mpared to the expansion of the vessel itself.

Displacements in each of the 3 directions for nozzle-disconnected case at the strain

sensitive equipment such as Pump/Turbine/Compressor nozzles shall be checked and

limited to as minimum (2mm) or practically as low as possible for alignment purpose.

In case of Tie -ins with existing facilities, displacements at tie-in points shall be

approximated based on a review of the existing piping and good engineering practice. Insuch cases, the piping configuration and restraints shall be done in such a way that

load/movement transfer to the existing piping system from the newly installed piping shall

not worsen the current opera ting conditions o f piping system . Refer Appendix-1 for details.

At Tie-ins to Christmas Tree equipment, thermal growth shall be considered in well head

piping design stre ss analysis as per data provided by Company. The calculated loads at

well head tie-ins shall be qualified based on the applicable flange load capacity charts as

per API TR 6A F Technical report on temperature De-rating on API Flanges under

combination of loading , in the absence of specific data on allowable loads. Ensure that

pipe is resting on the first support near the well head.

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. ~ DOC. TITLE :

Petrofac Piping Stress Analysis Design Basis J ?

PHASE -1(60MBOP O)P GE LOWER FARS HEAVY OIL DEVELOPMENT PROGRAM

On pipe racks displacement due to thermal expansion shall be limited so that adjacent lines

do not interfere with each other at changes in direction. When checking for interference

one line shall be considered at design temperature and the second line shall be considered

at minimum ambient temperature. Insulation thickness shall be taken into consideration for

insulated lines.

Structure deflection shall be considered where sensitive equipment is protected by the

piping support. The practical construction method shall be considered for piping support

design.

4. 13 Guides & Axial Stops

All the normal Guides and Axial stops are with a 3mm gap as per the Support Standard and

the same is ensured in field. Hence all the guides and axial stops shall be modeled in stress

analysis using a standard gap of 3mm, as this shall reflect the most realistic simulation of

the stress model so as to match the field condition. In the event non-standard gaps (other

than 3mm), are required as per stress analysis, this requirement shall be identified in the

IFC isometric drawings.

4 14 Decoupling

Lines that are not in critical criteria, tie-in to stress critical lines may have a significant

effect upon complete system flexibility Such lines shall be analyzed based on the criteria

given below. However any line not falling in below criteria but deemed to have effect on

stress system comprising critical lines due to its layout needs to be added to Stress critical

system.

DR)3

2:: 25 = IGNOREDs) 3

18 DR)3

25 NEEDS TO BE REVIEWED (close to nozzle shall have> <

=Ds) 3 impact)

DR)3 > 18 = TO BE ANALYSED

Ds) 3

Where,

DR- Nominal Diameter of Run Pipe

D8 Nominal Diameter of Branch Pipe

4.15 Loads on Equipment Nozzles

Nozzle loading shall meet the values specified in the project specification 15050901-000-00-

PI-SPC-0001 Specification for Allowable Nozzle Loads . Where allowable are not provided

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f

IPetrofac

-,DOC. TITLE :

®A ,I PAGE LONER FARS HEAVY O IL DEV ELOPMENT PROGRAM

· I PHAS E -1(60M BOP O)

Piping tress Analysis Design Basis

I r u 117of l .. o n t r a c t ~ ~ : 2~ ~ ~ ~ ~ 0 ~ _ j O . No. : · ~ 5 0 5 0 9 0 1 ? ~~? ~ P I B O D 0 0 0 ~ = _._.? ___ ______ : o m p a ~ ~ : . ~ ~~ ~ ~: ~~~

and have not been included in the equipment purchase order the calculated nozzle load

values shall be sent to the vendor for approval.

Piping shall qualify the nozzle load for pressure vessel as per table for allowable loads. If in

case one or more component is exceeding from the allowable limit then the same shall be

passed on to mechanical static vendor for approval.

4.16 Flange Leakage Checks

Flanges shall be reviewed to ensure that leakage does not occur due to the combined

effects of internal pressure and external loads. Where there is a concern regarding flange

leakage, flange Leakage Check shall be performed as per the following criteria to show

moments are acceptable. If calculations predict leakage then rerouting of piping, increasing

flange class or further in depth flange analysis shall be considered.

A) Flange with High Strength Bolting:

For flanges with bolting material having allowable stress at 38°C not less than 138

MPa shall be checked as per ASME Sec. Ill Division 1 - Subsection NC, Clause NC-

3658.3.

Mts ~ 3125 (Syf 36000) CAb

Mtd~

6250 (Sy/ 36000) C AbWhere

Mts = bending or torsion moment (considered separately) applied to the joint due to

weight, thermal expansion of piping, sustained anchor movements, relief valve

steady state thrust and other sustained mechanical loads applied to the flange joint

during the design or service condition, in.-lb).

Mtd = bending or torsion moment (considered separately) as defined for Mts but

including dynamic loadings applied to the flanged joint during the design or service

condition, (in . -lb).C bolt circle diameter, (in).

y yield strength of flange material at Design Temperature, (psi).

Ab = total cross-sectional area of bolts at root of thread or section of least diameter

under stress, (in 2) .

The value of yf 36000 shall not be taken as greater than unity.

B) Any other Flange Joints:

Flange not covered in the above category, leakage check shall be carried out based

on Equivalent Pressure method as per ASME SEC Ill Division1-Subsection NC, Clause

No. NC-3658.1 (a) & (b) as mentioned below.

Tightness of flanged joints is acceptable if:

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r-- ,OC. TITLE = T i .@-'p t f ~ Piping Stress Analysis Design Basis ?e ro ac VJ a 1 = = =

PAGE i LOW ERF ARSHEAVYOI LDE VELOPMENT PROGRAM

l ~ o n t r a c tN ~: : 15 5 9 1 __, DOC. o=:- 1 ~ 0 ~ ~ ~ : ~ ? = ~ 0 P ~ : ~ O D O o Q 2_ ~ E Y :: . ~ = ~~ ~ t ~ : m p a ~ ~ ; ~ : ~o ~ : ~; ; ~ ~ ; System Design Pressure + Peq <= 1.5 times Rated Pressure at Design or Service

temperature.

Peq=16Mrs (pi) * G 3)

Or

Peq=8Mrd (pi) * G 3

Where

Peq = Equivalent Pressure, (psi)

Mrs, Mrd = as defined above

G=Diameter at location of gasket load reaction, (in)

4 17 Pipe Sag

The design and spacing of pipe support shall be such that the maximum deflection between

any two supports does not exceed 13 mm. Offsite (Well blocks and Trunk lines) piping can\ have a maximum deflection of 25 mm. (This is as per clause 4. 7.2 of 15050901-000-00-PI BOD-0001 -Specification for Piping Design document)

4. 18 Acoustic Induced Vibration Flow Induced Vibration

Lines prone to Acoustic Fatigue shall be identified on the line list. The measures to be used

to safeguard against acoustic fatigue shall be identified by Process Consultants performing

AIVstudies.

Consideration should however, be given to recommendations contained within Energy

Institute Guidelines 'Guidelines for the Avoidance of Vibration Induced Fatigue in Process

Pipe Work' for general guidance.

4.19 Glass Reinforced Epoxy GRE) Pipe

GRE piping design shall be as per S EN ISO 14692 Part 3 or equivalent. Stress analysis of

GRE Piping should be performed by GRE Vendor. This is necessary so that GRE Vendor

remains fully responsible and contractually bound for the performance of the GRE piping

system. However, before giving the isometrics layouts to GRE vendor for stress analysis, i t

shall be reviewed by stress engineer for enough flexibility in the piping. This is to avoid

minimize pipe routing changes and requirement of extra thickness of pipes and fittings,

coming from GRE vendor due to stress analysis.

4 20 Pig Traps (Launcher/ Receiver)

For lines connected to Pig Traps (Launcher/Receiver), Stress analysis battery limits &

boundary conditions shall be agreedwith

Pipe line Group. Suitable extendof

pipeline up tofirst Anchor etc.) with respect to the Interface point shall be included in Piping Stress model

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DOC TITLE :

Petrofac Q A Piping St,., Analy•l• De•lgn ••• •I PAGE LONER FARS HEAVY OIL DEVELOPMENT PROGRAM

nI

I

~ ~ ~ ~ - ___H A _ s_E - ( 6 0 ~ ~ ~ ~ . _ .

~ o n t r a c t N o~~~ ~ ~ _ 9 ~ ~ C : N o : 1 5 0 5 0 9 0 1 - 0 0 0 - 0 0 P I B O D - 0 0 0 _ ~ ~ f, _c_ p_any _P_oJ_. N o~ E F / 1 8 5 2

so as to ensure appropriate end boundary conditions. The effect of Pipeline expansion shall

be included in Stress Analysis.

4. 21 Dynamic Analysis

Dynamic analysis shall only be used where vibration exists in brown field pipework or with

newly installed pipework local to reciprocating machinery where the reason for resonance is

not immediately apparent.

4. 22 Spring/Strut Supports/Snubbers/Sway Braces

4.23 The use of special supports like Spring supports & Strut supports shall be minimized by

I\ careful consideration of support location and alternative pipe routing. Spring supports shall

b eprotected from sand ingress.

4.24

~4.25

Expansion Joint, Swivel Joint/Hose

Flexible Joints such as expansion Joint, Swivel joint or flexible hose are not allowed without

the approval of Company.

Stress and Strain

Stress and strain analysis shall be done in compliance with ASME B31.3.

For sustained load, the SIF to be used for stress calculation shall be 0. 75i i is as per

Appendix D, ASME B31 .3) but SIF must not be less than 1.

For thermal EXP) case, Calculated Displacement Stress Range, S shall be limited to the

Allowable Displacement Stress Range, SA as per Eq. 1 b) Cl. 302.3.5.d of ASME B 31.3)

i.e. Liberal allowable stresses shall be used for qualifying the system in stress. ,

considering equivalent number of full displacement cycles as 7000.

For piping lift off from supports due to thermal movements , there is a weight stress re

distribution . Stress check at maximum operating condition shall be performed as per

Appendix P- B31 . 3, for cases where lift off> 2mm Typ).

The stress due to the resultant moment from a time independent, single non-repetitive

anchor movement such as predicted building settlement etc. shall be limited to 3 times of

Sc -Basic allowable stress at room temperature As per ASME Section Ill, Division I, NC-

3653.2b).

Stress for Occasional loads Wind/Seismic, etc . ) analysis shall be done in compliance with

ASME B31 . 3. The SIF to be used for Stress calculation for Occasional cases shall be 0. 75i i is

as per Appendix D, ASME B31 . 3) but 5 F must not less than 1

4.25. Allupset

cases including blas tcase

identified by process/HSE

shallbe

considered.

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r DOC. TITLE : 1

~,

Petrofac jJ) ~ 1Piping Stress Analysis Design Basis

I P GE i LON R FARS HEAVY OIL DEVE LOPMENT PROGRAMI i PHAS E -1(60M BOP O)

L: ~ t r a c t ~ ~~ - ~~ s_o___ _o_1 l_o c:~_o _ ~ ~ ~ ~ o 9 o 1 0_~ ~=~ ~~~~ o _~o _z_ = _ ~ ~ ~~~ - ~~ ~ r. J ; 1_ _

_~ ~ m ~ a : . yP r o j · ~ ~ :EF _1 s s z_ _ _ ~I5.0 RECORDS

No formal documentation is required for lines checked/reviewed by visual method.Formal documentation shall be prepared for the lines checked and reviewed by detailed

stress analysis.

It should include the following :

Report Summary

Reference Documents

Vendor Documents

Stress Isometrics

Caesar Input Report

Displacement Summary

Code Compliance

Restraint Summary

Hanger Report

Summary of Equipment Nozzle Loads

Flange Leakage Report

Calculation Sheet

Miscellaneous Data

Indicating the general information about the

lines, analysis data, and assumptions i any,

conclusion and recommendations

Extract of P ID, Extract of Critical Line List,

extract of PMS relevant to the Stress System.

Relevant Vendor drawings for the Equipment

detail applicable to the Stress System

Caesar-11 generated ISOGEN isometrics with all

nodes mark ups for Elbows, Tees, Branches,

Supports , Flange Joints, Equipment Nozzle and

Support.

Geometry, Mechanical properties, Design

conditions, Restraints.

For Sustained & Design Temperature.

Summary report for code stress check with the

maximum stress indicated.

With Displacement .

Where applicable.

Any applicable calculation sheets e.g. Slug Force

Calculation sheet.

If applicable , relevant e-mail/correspondence

references

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IPetrofac @

r ··· ··DOC. TITLE:

Piping Stress nalysis Design Basis

PAGE LOWE R FARS HEA VY O IL DEVELOPM ENT PR OG RAMPHA S E 1 {60 MBOPD)

Contract No. : 15050901

f · · · · · · · 21 of · · · · · · · · · ~ · · · · · ·IDOC. No. : 15050901-000-00-PI-BOD-0002 REV. : C I 26 L Company ProJ. No.: EF/1852 I

····-·--·----········--···-········-····-- -·---· ·- ·- · · · · ·- · · · · · · · · · ·· · · ------· · · · ·--· · · · ·- · · ·--· · · · · ·----· · · · - · - - - · - - · - · · · - - · · · - · · · · · ·-·---·-·-·-·----·-· · ·-· · · · · ·-· · · ·-· ·---· · ·-

SL. NO.

3

4

TYPE OF TIE IN

General for all tie-ins

Tie in to existingFlare linesothers

Tie in tohorizontal line

Tie in to Verticalline

APPENDIX 1

Stress Analysis Basis for Critical Lines near Tie-ins)

TYPICAL SKETCH

Existing l i n e /

~ 1 1 ~

E x i s t New

1- NowT xist

STRESS ANALYSIS APPROACH

Piping configuration and restraints for newpiping willbe done in such a way that loaddisplacement transfer to existing system isminimized and newly installed piping shallnot worsen the current operating conditionof the piping system .Suitable portion of existing line shall beincluded in the analysis by collecting theexisting line isometric with supporting

arrangement.In

the absence of the aboveinformation, displacements for existing lineat tie in point willbe approximated based onreview of existing piping good engineeringpractice . These displacements will be inputin stress analysis to check the stress levelsin new pipinQ.Existing Piping willbe reviewed to checklocation of existing anchors axial stops . Ifthere are no existing axial stops Anchors inthe horizontal run near tie in point, suitableaxial stop will be introduced in new pipingnear tie in point to isolate the new andexisting piping portions.Existing Piping will be reviewed to checklocation of existing anchors axial stops . Ifthere are no existing axial stops Anchors inthe Existing run near tie in point, suitableaxial stop will be introduced in new pipingnear tie in point to isolate the new andexisting piping portions.

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· · · · · · · ·

DOC. TITLE: 1

Piping Stress Analysis Design asis

PAGE LONER FARS HEAVY OIL DE VELOPME NT P ROGRM-tP HAS E -1 (60MBO P D)

IPetrofac

L~ ~ ~ ~ a c t ~ ~ : ~ ~ ~ o 9 o ~ _ ;~ ~ ~ ~~ ~ ~ ~ =~ ~ ? ~ ~ ~ ~ o o ? ~ ~ P ~ : B O ~~o o o z~ : =J ~ ~ ~ ~ ~~ ~ . : L _ ~ ~ ~ ~ ~~ ~ ~ _:_~ ~ ~ r o_j . : _ _i .~ ~ ~ : 2· : : ~ . =

APPENDIX-2(Seismic g Load Calculation as per Uniform Building Code)

Project: LFHO SEISMIC g LOADClient: KUWAIT OIL COMPANYJob No : Jl-2029 I CALCULA lON AS

Attachment toPER 1997 UNIFORM

Doc No :15050901-000 -00 -PI-BOD-0002 BUILDING CODE

INPUT I1) GEOMETRICAL INPUT

Soil Profile Type I SO

Seism ic Zone Factor.ZI 0.075

Seismic Source Type IfZ-0 .4)1 A

Distance from Source , Km IIZ=0.4JI

2) OTHER PARAMETERS

In Structure Component Amplification Factorap) As per UBC-97.Table16 -0 .Item 3.B)

Seismic Importance Fa ctor lp)As per UBC-97,Table16-K,SI no.4)

Component Response Modification Factor Rp)UBC-97,Table16-0 ,Item 3.B)

Element or Component Attachment Elevationwith respect to Grade h , ) I Stru cture Roof

Elevation with respect to Grade h,)

Rev ADate : 20 /03/2015Prep By: KP

Chkd y: GC

TO CONSIDER THE EFFECT OF PLANT PIPING PASSING THROUGHVARIOUS ELEVATIONhx/hr IS CONSIDEREDAS 0.5.

OUTPUT

Total Design Lateral Sei smic Force Fpas per UBC-97.Volume -2,Sec tion 1632,Equation 32-2)

Chec king of Section 1632 Equation 32-3:

Se ism ic "g" Load Factor for Input in StressCallc l a t o o n sf 1K ~ '

. etrofac

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® Piping Stce Analy i De,ign Ba.i

APPENDIX-3

Methodology for Trunkline Stress Analysis)

1 INTRODUCTION

1. 1. General

Scope of this document covers analysis of following lines by using the code listed asbelow in the table.

Sl No. Line Description Applicable code1 24 inch Steam Line ASME B 31.32 16 inch Steam Line ASME B 31.3

3 24 inch Product Line ASME B 31 34 8 inch Gas Line ASME B 31.85 18 inch Fire Water line ASME B 31 . 3

• The analysis will be carried out using the CAESAR II software latest version(7.0).

• The Minimum installation temperature shall be as per design basis as agreed .

• The Trunkline shall be modelled from Pig launcher to Pig Receiver .

• The Trunkline stress analysis shall be carried out for design pressure,operating temperature, minimum design temperature and Hydro testconditions.

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•

•

•

•

•

•

The guide gap specified on standard support details shall be used in theanalysis and the same shall be ensured at field. As per requirement of stressanalysis, any change in the guide gap against the standard guide gap shall behighlighted in Isometrics at respective nodes

Design factors shall be as per latest revision of the alignment sheets in linewith ASME B31 8 .

Pig Traps pig launcher/pig receiver) shall be included in the stress analysismodel and shall be verified against allowable axial movement at the pig trapsaddles.

The system shall be verified for over stresses and excess displacementconditions .

The Trunkline shall be analysed with the corroded condition at operatingcondition .

Any occasional loading due to slug, water hammer and seismic condition shallbe considered in the analysis.

Support, guide and anchor system shall be designed based on trunkline stressanalysis report for design load conditions.

For HP Steam Trunkline, mitigation plan of potential CIWH CondensateInduced Water Hammer) plan shall be established and Pipe Support shall bedesigned for potential steam hammering.

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2 0 INPUT DATA

2 1 Trunkline Data

•••••••••

•••••

2 2

2 3

The following input data will be considered in Trunkline Stress basis .Design CodePipe Size (inch)Pipe MaterialDesign Factor/ Wall ThicknessASME Class ratingMaximum Design Temperature, T1

Operating Temperatu re , T2

Minimum Design Temperature , T3

Installation/ Ambient Temperature

Design Pressure, PHydrostatic Test Pressure, HP

Process Fluid DensityCorrosion AllowancePoisson's Ratio

Bend Radius

Hot induction bends shall be used in design as agreed in Design basis. Bend radiusshall not be less than three times pipe diameter

Trunkline Anchor Load

All Trunklines will be laid above ground on sleepers and suitably anchored atstrategic points as guided by stress analysis. Loads on anchors will be checked withrespect to type of supports selected and simultaneous applicability of anchorguide loads based on various scenarios due to operating and occasional cases. TheTrunkline supporting system shall be designed based on above.

2 4 Movement at Supports

Movements at supports shall be checked to ensure that sufficient length of shoe has

been taken into consideration conditions.

2 5 Two Phase Flow

For two phase lines, proper supporting arrangement like sufficient guide, anchor andhold down shall be provided.

3. 0 LOAD CASES

The following load cases will be analysed in Trunkline Stress Model.

Case Load Case Type Combination Description

L1 HYD WW HP Hydro Test Run

L2 OPE W T1 P1 Oper. at Max Design Temp.

L3 OPE W T2 P1 Oper. at Normal OperatingTemperature

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L4 OPE W T3 P1 Oper. at Min. Design Temp.

L5 sus W P1 Sustain at Ambient Temp.L6 sus WNC Weight No Contents

L7 EXP L2-L5 Expansion at Max. Design Temp.

L8 EXP L4-L5 Expansion at Min. Design Temp.

L9 EXP L2-L4Expansion between Max. DesignTemp. and Min. Design Temp.

Occasional case like wind, transient or water hammer will be added in analysis,however, occurrence of any two of above at the same t ime will not be considered in

the analysis.

Legends Description

L Load Case

HP Hydro Test Pressure

HYD Hydro Test Case

OPE Operating Case

occ Occasional Case

sus Sustained Case

EXP Expansion Case

P Design Pressure

T1 , T2 Design/Operating Temperatures

T3 Min. Design Temperature

w Weight of piping components, Weight o f fluid etc

WNC Weight with no content

Pipe Weight + Water Weight

Live load and soil depths at road crossings shall be checked with respect to API RP

1102.

R SULTS

Stress Summary

Trunkline stresses at all critical points shall be checked against maximum allowable

stresses of applicable code.

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Displacements

Displacements at ig Trap terminal points shall be checked against allowable asindicated in the design basis.

Maximum Loads a t Above Ground Supports

Maximum load on all above ground Trunkline supports shall be checked forconstructability or feasibility point of view.

ON LUSION

The stresses, displacements and loads at all cases i.e. operating, sustained,expansion, occasional and hydro-test conditions) shall be checked whether they arewithin the acceptable allowable limits.