STRESS ANALYSIS REPORT

Client
End User
Project
P.O. No.
CPI Order No.
Stress Analysis Report No.

16.12.200
8
29.09.200
8
Issue

:
:
:
:
:

Galfar Engineering & Contracting (SAOG)

Petroleum Development of Oman
Qarn Alam Steam Project
MED 294355
O.O.0417.01
: CPI-SA-O0417-001 Rev.A

Issued for Approval

MV

PK

FM

Issued for Review &

Comments

MV

PK

FM

Rev

Revision Description

Prepared by

Checked by

Approved by

Page 1 of 6

Date

1. INTRODUCTION
The stress analysis has been carried out for the 10 and 6 GRE Pipeline
inclusive of station approach piping network for the Aquifer Pump-Off (APO)
system covered by the below mentioned drawings.
The CAESAR II Version 5.10, developed by COADE, Houston, Texas, has been
used for the analysis. CAESAR II is a PC based pipe stress analysis software
program used in the design and analysis of the piping systems and is based on
simple beam theory. The various types of loadings and piping details are given
in the input based on which the software produces results in the form of
displacements, loads and stresses throughout the piping system.
The GRE piping network is mainly of underground construction.
2. APPLICABLE CODES
The applicable code for the analysis is UKOOA. ISO 14692 is regarded as the
development of UKOOA code.
3. DRAWING NUMBERS AND CALCULATION NUMBERS
SL #
01
02
03
04
05
06
07
08
09
10
11
12
13
14
15
16
17
18
19

Drawing Number
QSP-450-MP-4024-37001-0001-A1-03
#3706)
QSP-450-LA-2373-37004-0001-A1-02
QSP-450-LA-2373-37004-0002-A1-02
QSP-450-MP-4024-37002-0001-A1-02
#3706)
QSP-450-LA-2373-37002-0001-A1-02
QSP-450-LA-2373-37002-0002-A1-03
QSP-450-LA-2373-37002-0003-A1-02
QSP-450-LA-2373-37002-0004-A1-02
QSP-450-LA-2373-37002-0005-A1-02
QSP-450-LA-2373-37002-0006-A1-02
QSP-450-LA-2373-37002-0007-A1-02
QSP-450-LA-2373-37002-0008-A1-02
QSP-450-LA-2373-37002-0009-A1-02
QSP-450-LA-2373-37002-0010-A1-02
QSP-450-LA-2373-37002-0011-A1-02
QSP-450-LA-2373-37002-0012-A1-02
QSP-450-MP-4024-37001-0001-A1-03
#3705)
QSP-450-LA-2373-37005-0001-A1-02
QSP-450-MP-4024-37003-0001-A1-02
#3705)

FWNETWORK

(well

Calculation Number
CPI-SA-0417-001
Rev.A

(well

(well

(well

Page 2 of 6

20
21
22

QSP-450-MP-4024-37001-0001-A1-03 (well
#3704)
QSP-450-LA-2373-37006-0001-A1-02
QSP-450-MP-4024-37003-0001-A1-02 (well
#3704)

4. MECHANICAL PROPERTIES & PIPE DATA FOR THE GRE

The mechanical properties of the GRE used in the analysis are as follows:
Density
: 1850 Kg/m3
Co-efficient of Thermal Expansion
: 18E-6 mm/mm C
Axial Modulus
: 12000 N/mm2
Shear Modulus
: 11400 N/mm2
Ea/Eh*Vh/a
: 0.3869
LTHS
: 125 MPa
Sa(0:1)/Sa(2:1)
: 0.517
GRE Pipe Data
ND (mm)
250
150
250
250
150

Structural Wall Thickness

(mm)
7.9
5.7
15
10
12

Remarks
Underground
Underground
Reinforced
Reinforced
Reinforced

GRE Fittings Data

ND (mm)
250 Elbow
150 Elbow
250 X 150 Tee
250 Elbow

Structural Wall Thickness

(mm)
17.38
12.54
26.07
20

Remarks
Underground
Underground
Underground
Reinforced

5. DESIGN CONDITIONS
The design conditions used in the stress analysis are as follows:
Design Pressure, P1
HydroTest Pressure, P2
Design Temperature, T1
Design Temperature, T2
Installation Temperature
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:
:
:
:

: 40 Bar
60 Bar
82 C for above ground
70 C for under ground
5 C
: 35C
Page 3 of 6

Fluid density

: 1000 Kg/m3

To meet the requirements of code, separate stress analysis runs has been
carried out with f2 factor 0.83 (Operating-sustained plus thermal), f2 factor 0.67
(Sustained) and f2 factor 0.89 (Occasional-Hydrotest)
6. ALLOWABLE STRESSES
The allowable stresses for the material calculated by the CAESAR II program are
as per UKOOA code and are listed in the attached stress report for the GRE
material
The part factor f2 is related to confidence in the GRE pipe system, the nature of
the application and consequence of failure. The assessment and evaluation of
the different loading conditions of the system has been analyzed considering
the different f2 factors as per UKOOA. The allowable stress values with different
f2 factors on different loading conditions are given below:
The allowable stress for f2=0.67 is 39.8 N/mm2 (Sustained)
The allowable stress for f2=0.83 is 49.3 N/mm2 (Sustained plus ThermalOperating)
The allowable stress for f2=0.89 is 52.8 N/mm2 (Occasional-Hydrotest)
7. DISPLACEMENTS
No displacements considered at the well head tie-ins intersections. The CS lines
are included in the model upto the well head anchor and the connecting CS
lines at the midline tie-ins with the 10 header. The well head anchor loads shall
be considered for the design of pipe supports. For the 10 pipeline, the
displacements (or) forces produced near the QASP (node no. 2450) shall be
incorporated in the on-plot stress analysis model. The stress ratios near the GRE
Tee (10 X 6) at the mid line tie-ins are given in the attached stress summary.
8. LOAD CASES
The following load cases considered in the analysis:
W+T1+P1 (OPE)
Case 1
W+T2+P1 (OPE)
Case 2
W+P1
(SUS)
Case 3
W+P2
(HYD)
Case 4
Where,
W = Weight of Filled Pipe
P1 = Design pressure, bar
P2 = Hydrotesting pressure, bar
T1 = Design temperature, oC
T2 = Operating temperature, oC

9. SUPPORTING

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Page 4 of 6

The support loads are shown in the attached restraint summary. The location
and type of supports are marked in the attached well hook up drawings. The
support structure shall be designed by client considering the respective support
loads from restraint summary.
The recommended support (Thrust block) for 10 underground GRE Pipeline
near the station approach has been listed down. The locations are identified on
the alignment sheets as given below. For loads refer to Table 2 for proper
design of Thrust blocks.
Table 1: Thrust blocks identification.
Node Number
Drawing Numbers
1200
QSP-450-MP-4024-37002-0001-A1 02
2350
QSP-450-LA-2373-37002-0012-A1 02

Table 2: APO - 10" GRE PIPE LINE THRUST BLOCK LOADS (N) AND MOMENTS (N-m)

NODE
NO
1200

44942

-1566

-90895

101410.73

866

-214

486

1015.84

2350

-47877

-2815

-81526

94586.57

911

-1

-534

1055.97

SL.NO

Fx

Fy

Fz

Fresultant

Mx

My

Mz

Mresultant

To over-come high stresses in few location of Pipeline the reinforced pipes and
fittings has been recommended to safe-guard the system. The location and
respective node numbers are mentioned in below tables for proper
identification.
Table 3: APO - PIPE REINFORCEMENT THICKNESS

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115

REF. PIPE
THICKNESS
(MM)
12

PIPE
LENGTH
(MM)
930

125

165

12

2784

150

495

545

12

2472

150

555

590

12

931

250

1060

1095

15

1745

250

1105

1195

15

2204

250

1205

1210

15

9000

250

2255

2295

10

10359

250

2335

2345

10

9000

10
11

250

2355

2395

15

2502

250

2405

2500

15

4822

12

150

2660

2695

12

930

13

150

2705

2795

12

2784

NODE NO

SL.NO

SIZE
(mm)

FROM

TO

150

80

150

Page 5 of 6

14

150

2955

3045

12

2366

15

150

3055

3090

12

922

16

150

3660

3685

12

930

17

150

3695

3795

12

2784

18

150

4055

4145

12

2667

19

150

4155

4190

12

922

Table 4: APO - ELBOW REINFORCEMENT THICKNESS

SL.NO

NODE NO

REF. ELBOW THICKNESS

(MM)

ANGLE

SIZE

QTY

1600

20

60O

250

20

250

250

2
3

1900
2250

20

60
45

10. CONCLUSION
All stresses are within the allowable limits if all the points specified in Section 9,
Remarks is followed as well as the piping system operates within the design
conditions as specified in the Section 5 of the report.
* * * * * * * * * *

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