SAUDI ARABIAN OIL COMPANY

DOCUMENT TITLE

STRESSS ANALYSIS REPORT FOR ABQQ-266 & 316 FLOWLINES

PROJECT NAME

ABQQ-266 & 316 (OIL) F/L C/S REPLACEMENT W/ RTR

PREPARED BY

FIBER GLASS SYSTEMS

Rev. No. 0 Date 10/08/2010 Description Issued for Review Prepared by AVE Checked by RH Approved by PI Cons ARAMCO

This document has been prepared for the titled project or named part thereof and should not be relied upon or used for any other project without an independent check being carried out as to its suitability and prior written authority of WPOE being obtained. WPOE accepts no responsibility or liability for the consequences of this document being used for a purpose other than the purposes for which it was commissioned. Any person using or relying on the document for such other purpose agrees, and will by such use or reliance be taken to confirm his agreement to indemnify WPOE for all loss or damage.

PO BOX 61335 JEBEL ALI FREE ZONE DUBAI UAE - TEL: +971-4-8865660 FAX: +971-4-886-5670

Sheet
PROJECT : Abqaiq flowlines JOB No. : REV./DATE

DFP-273
0 11/08/10

DOC .No. :

273-SRP-01

UNIT CLIENT

: ABQQ-266 & ABQQ-316 : Aramco

STRESS ANALYSIS REPORT

ATTACHED REFERENCE DOCUMENTS 1. 2. 3. ATTACHMENT "A" :

0 REV.

11/08/10 DATE

issued for approval DESCRIPTION

AvE PREPARED

GF CHECKED

AvE APPROVED

REVISED SHEETS ONLY ISSUED

O:\FORMS\ENG\GB03 24.01.97

ENTIRE DOCUMENT ISSUED

572

TOTAL NUMBER OF SHEETS

Dynaflow International Inc. Static Stress Analysis Report No. 273-SRP-01, Rev. 0 Issue date: 11-08-2010

Contents
1. Introduction ............................................................................................................... 3 2. Data used ................................................................................................................... 4
2.1 Design conditions ................................................................................................................................ 4 2.2 Material properties ............................................................................................................................... 4 2.4 Pipe content weight ............................................................................................................................. 5

3. Analysis ..................................................................................................................... 6
3.1 Static analysis...................................................................................................................................... 6 3.2 Boundary conditions & Assumptions ................................................................................................... 6

4. Results & Recommendations ................................................................................... 7 5. Conclusions ............................................................................................................... 8 Appendix 1 Stress Model ABQQ-266B Reference drawings ................. (4 pages) Appendix 2 Stress Model ABQQ-266B Input Listing ............................ (56 pages) Appendix 3 Stress Model ABQQ-266B Analysis results
Appendix 3a Displacements .................................................................................................... (30 pages) Appendix 3b Stresses in GRE piping .................................................................................... (195 pages) Appendix 3c Stresses in steel piping....................................................................................... (14 pages) Appendix 3d Loads on anchors ................................................................................................. (3 pages)

Appendix 4 Stress Model ABQQ-316B Reference drawings ................. (4 pages) Appendix 5 Stress Model ABQQ-316B Input Listing ............................ (46 pages) Appendix 6 Stress Model ABQQ-316B Analysis results
Appendix 6a Displacements .................................................................................................... (26 pages) Appendix 6b Stresses in GRE piping .................................................................................... (163 pages) Appendix 6c Stresses in steel piping....................................................................................... (14 pages) Appendix 6d Loads on anchors ................................................................................................. (3 pages)

Dynaflow International Inc. Static Stress Analysis Report No. 273-SRP-01, Rev. 0 Issue date: 11-08-2010

1. Introduction
In this report the static stress analysis results are presented for the 6 and 8 GRE flow lines from wells ABQQ-266 and ABQQ-316 at the Abqaiq field. The lines are fully underground. The length of each of the lines is approximately 620 m. The CAESAR II v.5.2 pipe stress analysis software has been used for modeling and analysis. The system has been analyzed conform the rules of ISO-14692. Pipe stresses have been assessed using the allowable stress envelope for the applicable material. The pipe manufacturer, M/s Fiber Glass Systems, has provided data for the construction of the stress envelope. This report is based on the following drawings: Drawing No. BB-544591 sheet 001 BB-544591 sheet 002 BB-429910 sheet 001 BB-429910 sheet 002 revision A A A A

Input and output data have been attached in the appendices. The following has been provided: 1) Marked-up copy of drawings showing node numbers used in the analysis (only the most important node numbers have been indicated. Marking all node numbers would make the illegible). 2) Computer input listing. 3) Analysis results comprising of : a. Displacements of each node. b. Stresses at each node. c. Stress envelope indicating highest stress for each load case. d. Loads on anchors at start and end of flow lines.

Dynaflow International Inc. Static Stress Analysis Report No. 273-SRP-01, Rev. 0 Issue date: 11-08-2010

2. Data used
The following data has been used for stress calculations: 2.1 Design conditions Design pressure: Hydrotest pressure: Max. design temperature: Min. design temperature: Installation temperature: pdesign ptest Tmax Tmin Tinst = 93.1 barg = 139.5 barg = 93 C = 5 C = 21 C

2.2 Material properties Material: Structural wall thickness: GRE by M/s Fiber Glass Systems ND 150 ND 200 10.3 mm , 14.0 mm

Elasticity modulus: Shear modulus: Poisson ratio:

Eaxial Ehoop G hoop/axial axial/hoop

= 17030 MPa = 28131 MPa = 11000 MPa = 0.6 (hoop load) = 0.36 (axial load) = 15.7*10-6 mm/mm/C = 1.85

Thermal expansion coeff. Specific gravity

Allowable Stresses The following data has been used to construct the allowable stress envelope: DN 150: Qualified stress Axial strength at zero pressure jqs = 116.6 MPa Ssa(0:1) = 68.9 MPa

Hoop strength at 2:1 pressure condition Ssh(2:1) = 247.9 MPa DN 200: Qualified stress Axial strength at zero pressure jqs = 116.1 MPa Ssa(0:1) = 68.9 MPa

Hoop strength at 2:1 pressure condition Ssh(2:1) = 221.3 MPa

Dynaflow International Inc. Static Stress Analysis Report No. 273-SRP-01, Rev. 0 Issue date: 11-08-2010

Part factor f2

f2 f2 f2

= 0.67 (sustained) = 0.83 (operating / design) = 0.89 (hydrostatic test / occasional)

2.4 Pipe content weight Pipe content density (wet crude) = 800 kg/m3

Dynaflow International Inc. Static Stress Analysis Report No. 273-SRP-01, Rev. 0 Issue date: 11-08-2010

3. Analysis
3.1 Static analysis Based on the design conditions, in the static analysis, the following basic load cases have been considered:

Load case 1 Load case 2 Load case 3 Load case 4

Design [liquid filled pipe weight (W) + design temperature (T1) + design pressure (P1)] Design [liquid filled pipe weight (W) + design temperature (T2) + design pressure (P1)] Sustained [liquid filled pipe weight (W) + design pressure (P1)] Hydrotest [liquid filled pipe weight (W) + hydrotest pressure (P2)]

Where,

Maximum design temperature, T1 = 93 C Minimum design temperature, Design pressure, Hydrotest pressure, T2 = 5 C P1 = 93.1 barg P2 = 139.5 barg

3.2 Boundary conditions & Assumptions The models have been terminated at the anchors located at the start and end of the lines. The short section of steel pipe between the GRE and the anchor has been included in the model.

Dynaflow International Inc. Static Stress Analysis Report No. 273-SRP-01, Rev. 0 Issue date: 11-08-2010

4. Results & Recommendations

The results of the calculations are attached in the appendices. The computer results show that stresses for all loadcases are within allowable limits.

The anchors at the start and end of the lines should be designed for the following axial loads (loads in other directions are negligible):

DN 150: 130 kN DN 200: 250 kN The above-listed forces are unfactored.

It is recommended to fully backfill the lines before hydrotesting. Only joints should be left exposed.

The table below summarizes the maximum calculated stresses for each model and load case: Percentage Allowable (%) 70.0 60.0 86.7 97.7

Model

Load case OPE 1 OPE 2

Node 234 22 344 344

Axial Stress (MPa) 9.2 29.4 25.8 38.5

Hoop Stress (MPa) 67.4 67.4 67.4 101.0

Code Stress (MPa) 67.4 67.4 67.4 101.0

ABQQ-266 SUS OCC

Model

Load case OPE 1 OPE 2

Node 250 464 250 280

Axial Stress (MPa) 9.4 29.9 25.7 38.5

Hoop Stress (MPa) 67.8 67.8 67.8 101.6

Code Stress (MPa) 67.8 29.9 67.8 101.6

Percentage Allowable (%) 70.4 71.6 87.2 98.3

ABQQ-316 SUS OCC

The above-listed maximum stresses are plotted on the allowable stress envelopes attached in appendix 3 and 6. It is clear from the graphs that stresses are within allowable limits for all load cases.

Dynaflow International Inc. Static Stress Analysis Report No. 273-SRP-01, Rev. 0 Issue date: 11-08-2010

5. Conclusions
It may be concluded from the computer results that, upon implementation of the recommendations as mentioned in section 4: 1. Static pipe stresses are acceptable.

2. It is recommended to fully backfill the lines before hydrotesting. Only joints should be left exposed.

3. The anchors on the DN 150 flow line should be design for an axial force of 130 kN. The anchors on the DN 200 flow line should be designed for an axial force of 250 kN.

Dynaflow International Inc. Static Stress Analysis Report No. 273-SRP-01, Rev. 0 Issue date: 11-08-2010

Appendix 1 Stress Model ABQQ-266B Reference drawings

Dynaflow International Inc. Static Stress Analysis Report No. 273-SRP-01, Rev. 0 Issue date: 11-08-2010

Appendix 2 Stress Model ABQQ-266B Input Listing