GAMBA EXPORT LOADING LINE (SHELL GABON)

Wall thickness Report

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Date
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REVISION CONTROL SHEET

REV.NO SECTION NO. SUMMARY OF CHANGES

B Table 4.1 WT changed
B Table 4.2 WT changed
B Table 5.2 Design parameters confirmed
B Table 6.2 WT changed
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TABLE OF CONTENTS

1.0 INTRODUCTION .............................................................................. 4

General ......................................................................................... 4
Scope of work ............................................................................... 4
2.0 UNITS, ABBREVIATIONS & NOMENCLATURES .......................... 6
System of Units ............................................................................. 6
Abbreviations ................................................................................ 6
Nomenclature ................................................................................ 6
3.0 REFERENCE DOCUMENTS ........................................................... 9
Company Engineering Standards .................................................. 9
International Codes, Standards and Guidelines ............................. 9
Project Reference Documents ....................................................... 9
4.0 SUMMARY, RESULTS, CONCLUSIONS & RECOMMENDATIONS10
Summary & Results ..................................................................... 10
Conclusions & Recommendations ............................................... 10
5.0 DESIGN DATA .............................................................................. 12
Fluid category .............................................................................. 12
Design Pressure & Temperature ................................................. 12
Line Pipe Design Data ................................................................. 13
Corrosion Allowance ................................................................... 13
Design Factors ............................................................................ 13
Dimensional Tolerances .............................................................. 14
Water depth & Ground Elevation along the route......................... 14
Tidal and Wave data ................................................................... 15
6.0 DESIGN METHODOLOGY ............................................................ 16
General ....................................................................................... 16
Required Wall thickness .............................................................. 16
Pressure Containment ................................................................. 17
Hydrostatic Collapse due to External Pressure ............................ 17
Propagation Buckling................................................................... 18
Design Loads .............................................................................. 18
Results ........................................................................................ 19
APPENDIX A – WALL THICKNESS CALCULATIONS .................................. 20
 GAMBA EXPORT LOADING LINE (SHELL GABON)

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1.0 INTRODUCTION

General

Shell Gabon is operating and producing oils from numerous fields located in the
western part of Gabon. Crude is treated and exported from the Gamba Terminal
to tankers through a 30 inch dual offshore export line connected to a SBM via a
PLEM and 2 x 16 inch floating hose strings (risers).

The total length of the existing export line is about 10.7km from the export pump
in Gamba terminal to a PLEM (1.3km located onshore and 9.4km located
offshore).

Figure 1-1: Project Location

Shell Gabon intends to replace the existing export pipeline. Zeetech B.V. has been
awarded by Shell to perform a concept replacement study for dual pipelines and
Front End Engineering Design (FEED) for the selected concept.

Scope of work

The wall thickness of the both offshore and onshore 22 inch Gamba Export dual
pipelines with material grade API 5L X-65 are calculated based on the following
failure modes have been considered in this analysis.

 Internal Pressure containment as per ASME B31.8 & ISO 13623

 Propagating buckle pressure & Collapse as per API RP 1111
 GAMBA EXPORT LOADING LINE (SHELL GABON)

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PROJECT NUMBER: 13027 Sht. No. Rev. No.
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The required wall thickness has been calculated by taking into account of the
corrosion allowance and fabrication tolerances. The selected wall thicknesses are
determined in accordance to API SPEC 5L standard wall thickness.
 GAMBA EXPORT LOADING LINE (SHELL GABON)

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2.0 UNITS, ABBREVIATIONS & NOMENCLATURES

System of Units

In accordance with Shell DEP 00.00.20.10. (Ref. [1]), the International System (SI)
of units is adopted as the main system of units unless noted otherwise.

Abbreviations

API American Petroleum Institute

ASME American Society of Mechanical Engineers
DEP Design Engineering Practice
FEED Front End Engineering Design
HAT Highest Astronomical Tide
ISO International Standard
LAT Lowest Astronomical Tide
MAOP Maximum Allowable operating Pressure
MSL Mean Sea Water Level
OD Outside diameter
PLEM Pipeline End Manifold
RP Recommended practice
SBM Single Buoy Mooring
SI International System of Units
SMYS Specified minimum yield strength
SPEC Specification
TBC To be Confirmed
WD Water Depth

Nomenclature

Ap Area of Pipe
D Outside Diameter
DFoff Design factor offshore pipeline
DFon Design factor onshore pipeline
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dmax Design water depth for collapse & buckling criteria

dmin Design water depth for Hoop stress criteria
E Young’s modulus
fo Collapse factor
fp Propagating buckling factor
Hmax Wave Height
HWL Highest water level
oC Temperature in degrees Celsius
Pb Specified minimum bursting pressure
Pc Collapse pressure
Pe Elastic collapse pressure
Pe_max External Hydrostatic pressure for Collapse &
Buckling
Pe_min External Hydrostatic pressure for hoop stress
PiH Maximum Operating Pressure
Pp Critical buckling pressure
Py Yield pressure at collapse
Ta Axial tension in pipe
tCA Corrosion allowance thickness
Teff Effective tension in pipe
tf Fabrication tolerance thickness( 8% of tprovide)
tmin Minimum pipeline wall thickness
tminI Minimum pipeline wall thickness based on D/t ratio
tminp Minimum thickness including Corrosion allowance
tprovide Final thickness of pipeline
treq Required thickness
Ty Yield tension in pipe
U Minimum ultimate tensile strength
UCcom Combined load check
WDmax Maximum water depth
WDmin Minimum water depth
ϑ Poissons ratio
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ρsea Seawater density

σa Axial stress in pipe wall
σhd Circumferential hoop stress due to Fluid pressure
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3.0 REFERENCE DOCUMENTS

The following company standards, codes and standards have been utilized in the
wall thickness calibration.

Company Engineering Standards

[1] Shell DEP 00.00.20.10, the Use of SI Quantities and Units, 2005.
[2] Shell DEP 31.40.00.10, Pipeline Engineering (amendments/ supplement to
ISO 13623), 2010.
[3] Shell DEP 34.00.01.30, Minimum Requirements for Structural Design and
Engineering, 1998.
[4] Shell DEP 34.28.00.31, Steel Structures, 1996.

International Codes, Standards and Guidelines

[5] ISO 13623, Petroleum and Natural Gas Industries, Pipeline Transportation
Systems, 2009.
[6] DNV OS F101, Submarine Pipeline Systems, 2010.
[7] API RP 1111, Design, Construction, Operation and Maintenance of Offshore
Hydrocarbon Pipelines– Limit state Design, 2009.
[8] ASME B31.8, Gas Transmission and Distribution Piping Systems, 2007.
[9] API Specification 5L, Specification for Line Pipe, 44th Edition, 2007.

Project Reference Documents

The following related project documents are referenced.

[10] Design Basis Doc. No:13027-ER-001
[11] Concept Evaluation - Gamba Export Loading Line, Doc.No: Z.100.1.
[12] Gabon Metocean Geophysical and Environmental data collection, Doc. No:
GSL-08207-GPH-003.
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4.0 SUMMARY, RESULTS, CONCLUSIONS & RECOMMENDATIONS

Summary & Results

This section presents the summary of results in accordance with the calculations
performed in Appendices A of this report.

The analyses have been performed considering the following pipe outer
diameters, material grade and manufacturing process:

 22 inch (559 mm) Outer Diameter Pipe, API Spec 5L - X65 Material Grade
(Seamless).

Analyses have been performed to confirm the required wall thicknesses for the
above mentioned pipe parameters for the following assessment criterion:

 Pressure Containment(bursting)
 Hydrostatic System Collapse
 Buckle Propagation

Design methodology of the above-mentioned analyses has been presented in

Section 6.0 of this report. Based on the calculations performed, the results have
been summarized in the following table.

Table 4.1: Summary of wall thickness Results

Pipe Material tCA Governing tf Minimum Selected
OD(mm) Grade (mm) Load Case (mm) Required WT(mm)
WT(mm)
559 X65 0.0 Hydrotest 8% 5.74 10.0
559 X65 3.0 Internal Pressure 8% 8.74 10.0

Conclusions & Recommendations

The proposed wall thickness for dual pipelines is based on API 5L Specification
Standard wall thickness and meets all requirements of the wall thickness checks.
 GAMBA EXPORT LOADING LINE (SHELL GABON)

Wall thickness Report

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It is recommended that a single wall thickness fulfilling all wall thickness checks
be proposed for both offshore and onshore sections. The results are tabulated in
the following table.

Table 4.2: Recommended wall thickness from PLEM to landfall

Pipe Material WT(mm) D/t
OD(mm) Grade
558.8 X65 10.0 58.84

Note:
 No buckle arrestors are required based on the cases analyzed for buckle propagation in
the calculations.
 The Diameter to the wall thickness (D/t) ratio for the recommended wall thickness is in
accordance with reference [2].
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5.0 DESIGN DATA

Unless otherwise stated, all design data considered in the wall thickness
calculations for the proposed offshore pipeline, presented in the following
subsections, have been obtained from the Specification –Design Basis (Ref. [10]).

Fluid category

Fluids transported by the pipeline system are to be categorized according to their

hazard potential with respect to public safety (Reference.2, Table 1).

Table 5.1: Categorization of Fluids

Fluid Description
Category
A Typical non-flammable water-based fluids.
B Flammable and/or toxic fluids that are liquids at ambient temperature
and at atmospheric pressure conditions. Typical examples are oil and
petroleum products. Methanol is an example of a flammable and toxic
fluid.
C Non-flammable fluids that are non-toxic gases at ambient temperature
and atmospheric pressure conditions. Typical examples are nitrogen,
carbon dioxide, argon and air.
D Non-toxic, single-phase natural gas.
E Flammable and/or toxic fluids that are gases at ambient temperature and
atmospheric pressure conditions and are conveyed as gases and/or
liquids. Typical examples are hydrogen, natural gas (not otherwise
covered in category D), ethane, ethylene, liquefied petroleum gas (such
as propane and butane), natural gas liquids, ammonia and chlorine.

As the product to be transported through the pipelines oil, the product belongs to
Category B.

Design Pressure & Temperature

The operating/ design pressure and temperatures have been extracted from
design basis (Ref. [10]) and presented in the following table.
Table 5.2: Design Pressure & Temperature
Parameter Unit Value

Design Pressure barg 60

o
Design Temperature C 60
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Line Pipe Design Data

The line Pipe material properties extracted from the Design Basis (Ref. [10]).and
are tabulated in the following table.

Table 5.3: Line Pipe material Properties

Parameter Unit Value

Dual pipelines OD mm 559(22”)

Material Grade - API 5L X65
Specified Minimum Yield Stress Psi/MPa 65000/448
Young’s Modulus MPa 207 x 103
Density kg/m3 7850
Poisson’s ratio ϑ 0.3

Corrosion Allowance

The corrosion allowance 3.0mm shall be considered as specified by Company.

Design Factors

Design factors considered for the wall thickness analysis as tabulated below table.

Table 5.4: Design Factors

Description Value
offshore onshore
General 0.77 -
Landfall 0.67 -
Hoop stress General route - 0.77
design factor Crossings - 0.67
Temperature derating factor 1.0
Collapse design factor, fo 0.70
Propagating buckling design factor, f p 0.8
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Dimensional Tolerances

Dimensional tolerances for the dual pipelines are as follows, in accordance API
Spec 5L for Line Pipe (Ref. [9]):

- Wall thickness: -8%, +19.5%

- Out of roundness: no greater than 0.75

Water depth & Ground Elevation along the route

The maximum water depth along the offshore pipeline are taken from the Design
basis (Ref. [10]).

Figure.5-1: Seabed profile along the Existing Pipeline route.

Figure.5-2: Ground Elevation along the Existing Pipeline route

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Table 5.5: Water Depth

Description KP (from – To) Min.Water Depth (m) Max.Water Depth (m)

Offshore dual Pipelines 0.000-10.700 0.0 24.0

Tidal and Wave data

Tidal and wave data considered in the design are taken from the Gabon LNG
Metocean Geophysical and Environmental data (Ref. [12]) and those values are
tabulated as below:
Table 5.6: Tidal & Wave data
Description Unit Height

Highest Astronomical Tide(HAT) m 1.99

Mean Sea Level ( MSL) m 1.01
Max.Wave Height, Hmax (Assumed) m 7.0
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6.0 DESIGN METHODOLOGY

General

This section presents the design methodology for the wall thickness checks for the
proposed dual pipelines. Pipeline wall thickness shall be calculated in accordance
with API RP 1111, ISO 13623 & ASME B31.8 (Ref. [7], Ref. [5] & Ref. [8]) to ensure
that the pipelines are strong enough to withstand both the Operating and Hydrotest
conditions.

Wall thickness design shall also consider collapse and buckle propagation due to
external Hydrostatic pressure.

Figure.6-1: Dual Pipelines concept layout.

Required Wall thickness

The required wall thickness shall considerer corrosion allowance and fabrication
tolerance as follow:

𝑡𝑟𝑒𝑞 = 𝑡𝑚𝑖𝑛 + 𝑡𝐶𝐴 + 𝑡𝑓 (Eq.6.2.1)

The final selected wall thickness refers to API Spec. 5L and shall be not less than
𝑡𝑟𝑒𝑞 .
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Pressure Containment

The hoop stress formula in API RP 1111 is used to determine minimum required
wall thickness for the dual pipelines. The analyses are performed for the Hydrotest
and Operating conditions.

In this analysis, the minimum required wall thickness is calculated based on the
net internal design pressure, design factor, fabrication tolerance, corrosion
allowance, pipe outside diameter and the SMYS of the line pipe.

The minimum required wall thickness for a given net internal design pressure is
determined using the following formula:

(𝑃𝑖𝐻 −𝑃𝑒_𝑚𝑖𝑛 )(𝐷−𝑡𝑚𝑖𝑛 )

𝜎ℎ𝑑 = (Eq.6.3.1)
2𝑡𝑚𝑖𝑛 𝐷𝐹𝑜𝑓𝑓

Hydrostatic Collapse due to External Pressure

The pipeline shall be designed to resist collapse due to external pressure in

accordance with API RP 1111(Ref. [7]).

Hydrostatic Collapse shall be checked for operation condition considering a

corroded, non-pressurized pipe for a depressurization case.

According to section 4.3.2.1 of API RP 1111, the collapse pressure of the pipe
must exceed the net external pressure everywhere along the pipeline as follows:

Collapse Pressure,
𝑃𝑦 𝑃𝑒
𝑃𝑐 = (Eq.6.4.1)
√(𝑃𝑦 2 +𝑃𝑒 2

Yield Pressure at Collapse,

𝑡𝑚𝑖𝑛
𝑃𝑦 = 2 𝑆𝑀𝑌𝑆 ( 𝐷
) (Eq.6.4.2)
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Elastic Collapse Pressure,

𝑡
2 𝐸 ( 𝑚𝑖𝑛 )
𝐷
𝑃𝑒 = (1−𝜗2 )
(Eq.6.4.3)

Permissible Criteria Check,

𝑃𝑒_𝑚𝑎𝑥 − 𝑃𝑖𝐻 ≤ 𝑓𝑜 𝑃𝑐 (Eq.6.4.4)

Propagation Buckling

The propagation buckling pressure shall be determined in accordance with API

RP 1111 (Ref. [7]). Any requirements such as increased line pipe wall thickness
or using buckle arrestors shall be assessed in this section.

The use of buckle arrestors regularly spaced along the pipeline length potentially
subject to propagation buckling will be preferred to an increase of the pipeline wall
thickness.

The propagation buckling assessment has been performed for the pipeline lying
on the seabed after installation, empty and without any internal pressure.

Critical Propagation Buckling Pressure,

𝑡𝑚𝑖𝑛 2.4
𝑃𝑝 = 24 𝑆𝑀𝑌𝑆 ( 𝐷
) (Eq.6.5.1)

Permissible Criteria Check,

𝑃𝑒_𝑚𝑎𝑥 − 𝑃𝑖𝐻 ≤ 𝑓𝑝 𝑃𝑝 (Eq.6.5.2)

Design Loads

The load combinations to be considered in the wall thickness analysis for the
operating & Hydrotest conditions are summarized below:
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Table 6.1: Design loads for Wall thickness analysis

Design Load Design Condition
Pressure Containment Collapse Buckling Propagation Buckling
Operating Hydrotest Operating Operating
Internal design hydrotest de-pressurized de-pressurized
Pressure pressure pressure
Corrosion 100% tCA un-corroded 100% tCA removed un-corroded
allowance removed
Fabrication tf removed tf removed tf removed tf removed
tolerance
Water Depth min.WD min.WD max.WD max.WD

Note:
1. Water depths are in accordance with Section 5.7

Results

Based on Mathcad sheets are attached in Appendix A, results of wall thickness

calculation for the 22 inch dual pipelines is presented in the following Tables.
The wall thickness has been selected in accordance with the wall thickness
presented in API 5L specification. No buckle arrestors are required.
The analyses performed herein satisfy the requirements for wall thickness checks
for the pre-project engineering stage.

Table 6.2: Wall thickness Results

Pipe Material tCA Governing tf Minimum Selected
OD(mm) Grade (mm) Load Case (mm) Required WT(mm)
WT(mm)
559 X65 0.0 hydrotest 8% 5.74 10.0
559 X65 3.0 Internal pressure 8% 8.74 10.0
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APPENDIX A – Wall Thickness Calculations

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