PROVISION OF EPCIC AND LEASING

FOR LAYANG FPSO FACILITIES

Purchase Order Number:

H100000271-1

Purchase Order Title:

PROJECT OF SUPPLY COMPLETE PACKAGE OF FLOATING

HOSE AND MARINE BREAK AWAY COUPLING FOR
LAYANG FPSO PROJECT
MIBITALIANA S.P.A.

Vendors Name:
Vendors Reference Number and Revision:

Rev.

Vendor (Prepared By)

Vendor (Checked By)
Vendor (Approved By)

Document Description: MBC - Surge Analysis Report

Equipment / Tag Number(s): MARINE BREAK AWAY COUPLING
Project No.
LFPSO

Purchase
Order

VDR
Code

Sequential No.

H10000027
1-1

C99

00002

Sheet No.
(Applicable for
drawing only)

Rev
No.
00

Also Covers
VDRL codes
Purchaser review and comments shall not be assumed to indicate either responsibility or liability for
accuracy and completeness of this document or to alter any contractual terms and conditions.

Review Code and Status

Code 1
Code 2
Code 3
Code 4
Date:

Approved - Final
Accepted with Comments Noted Incorporate Comments, Up-rev and
Resubmit. Work may Proceed
Review not required Do not re-submit
Rejected - Do not proceed, revise and re-submit
Sign:
TH HEAVY ENGINEERING

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SURGE ANALYSIS

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DESIGN & ENGINEERING DEPT.

EQUIPMENT:
ATTREZZATURA:

MIBREAK 12 FB ASME B16.5 CL. 150

PRODUCTS:
PRODOTTO:

CRUDE OIL

DRAWING No:
DISEGNO N:

HB0090

CUSTOMER:
CLIENTE:

TH HEAVY ENGINEERING

PROJECT NAME:
PROGETTO:

TH HEAVY ENGINEERING BERHAD

FPSO LAYANG

MIB PROJECT REF.:

RIFERIMENTO MIB:

25442 / OF9033

CUSTOMER REF.:
RIF.TO CLIENTE:

P.O. H100000271-1 DATED 27/05/2015

SERIAL Nr.:
N DI MATRICOLA:

AA0002

08.10.15

NR

MZ

RK

First issue

Rev.

Date

Issued

Checked

Approved

Description

Issued by:

Checked by:

Approved by:

Name: A. Deponti

Name: N. Rossetto

Name: R. Krss

Sig:

Sig:

Sig:

Date:

AD
06.10.2015

Date:

NR
07.10.2015

Date:

RK
08.10.2015

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TABLE OF CONTENTS

1. INTRODUCTION ................................................................................................... 3
2. FLUID DYNAMIC MODEL OF THE LINE ............................................................. 3
3. PETALS CLOSURE SEQUENCE ....................................................................... 11
4. SURGE ANALYSIS............................................................................................. 12
5. FUNCTIONAL TEST ........................................................................................... 14
6. CONCLUSIONS .................................................................................................. 16

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OR 1.5 times the design
pressure of topsides piping
whichever is lower

INTRODUCTION

1.

A surge analysis is performed to define the closure time for the MIBreak unit in order
to avoid an overpressure higher than 1.33 times the design pressure, due to the
water hammer effect.
A steady state analysis of the operating condition is first performed, to calculate the
fluid-dynamic conditions before activation of the MIBreak unit.
After this, a closure of the MIBreaks petal valves against the flow is simulated in
order to calculate the quickest closure time that produces a peak of pressure limited
to 25.3 bar (1.33 x 19 bar). This closure time is correlated with the geometry of the
dampening system, which is therefore fixed.
With the geometry of the dampening system defined above, a further analysis is
performed to simulate the functional test during the FAT, when the closure time will
be checked. As the FAT is performed with the unit empty, the corresponding closure
time will be longer than the calculated above as there will be no load from the flow
acting on the petals and the petals are forced to close only by the springs of the
peak pressure shall govern by
mechanism.
piping downstream of check

valve 350-C-052 ie 24barg (1.5

FLUID DYNAMIC MODEL OF THE LINE

2.

* 16 barg)

As written above a steady state analysis of the operating condition is first performed,
to calculate the fluid-dynamic conditions before activation of the MIBreak unit.
The system is modelled by means of a one-dimensional computational-fluid-dynamic
(CFD) approach using the software Flowmaster.
The model is shown in Fig. 1, based on data defined in the following documents:

OFFLOADING HOSE LENGTH AND HYDRAULIC CALCULATION

TECHNICAL NOTE
Document THE-STE-LFPSO-11E-PP-LYT-80002 Rev A Piping Layout
Drawing - Cargo Oil System (Main Deck)
LFPSO-H100000271-1-C01-00001 Rev A HBO General Arrangement
Drawing String Layout
THE-STE-LFPSO-11E-PP-PID-80002 Rev 1 P&ID Cargo Oil System
Dual Plate Check Valve characteristic.pdf
HP-27-28-29-30-31-32-33 Gene Piping Arr. In Pump Rm.
REF#4 THHE - Caratteristiche Tubi - 22-06-2015.xlsx
REF#9 LFPSO-H100000271-1-C01-00001 - Rev00.pdf
Data required for Pressure Surge Analysis - from THHE - Engi Soft.docx

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is this HBU? is yes show

'HBU' tag

DESIGN & ENGINEERING DEPT.

Fig. 1. One-dimensional fluid-dynamic model.

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Here below the technical assumptions made for this analysis are reported, based on
what discussed and clarified with the client.

One pump is considered. Pump elevation above reference is null. Pump

characteristics are based on data presented at page 4 of document
OFFLOADING HOSE LENGTH AND HYDRAULIC CALCULATION
TECHNICAL NOTE. In particular, the flow rate through the pump is 2000
m3/h, the rotational speed is 1500 rpm and the total head at 2000 m3/h is
130.8 m. The pump characteristic curve is presented in Fig. 2.

Fig. 2. Pump characteristic curve.

Piping from the pump (point A) to point B is modelled based on drawing

HP-27-28-29-30-31-32-33 Gene Piping Arr. In Pump Rm. As indicated, pump
No. 2 and line CP-11 are considered. All the pipes in this section are DN450.
Pipe lengths are presented in
Fig. 3. Elevations are presented in
Fig. 4. Point B has an elevation of 23.3 m above point A (pump). No valves
are considered. Junctions connecting line CP-11 to the new line are modelled
by means of mitre bend which are equivalent to tee junctions with one closed
arm.

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Fig. 3. Pipe lengths in section AB.

Fig. 4. Elevations in section AB.

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The total length of pipes (excluding bends) between points A and point B
derived from the detailed pipe routing is 83.1 m.

Piping from point B to point C is modelled (elevations, diameters, lengths,

elbows, valves) based on document THE-STE-LFPSO-11E-PP-LYT-80002
Rev A Piping Layout Drawing - Cargo Oil System. Pipes diameters vary from
a minimum of DN300 and a maximum of DN600 so that also transitions are
modelled. Pipe lengths are presented in
Fig. 5. Elevations are presented in
Fig. 6. Point C has an elevation of 21.5 m above point A (pump). The dual
plate check valve 350-C-052 is modelled on the base of document Dual Plate
Check Valve characteristic.pdf. Its closing time is 0.5 seconds. From the
graph it can be derived that the pressure drop of the DN500 valve with a flow
rate of 2000 m3/h is 0.0358 bar.

Fig. 5. Pipe lengths in section BC.

Fig. 6. Elevations in section BC.

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The total length of pipes (excluding bends) between points B and C derived
from the detailed pipe routing is 91.15 m.

Valves and elbows are considered between point B and point C while side
branches are neglected.

Valves are modelled based on Flowmaster component database as follows:

o Valves 350-V-132 and 350-V-022 are modelled as butterfly valves;
o Valve 350-C-052 is modelled as a swing check valve;
o Valve 350-XOV-021 is modelled as a globe valve.
Valve pressure drops at 2000 m3/h are reported in
Tab. 1.
Valve
350-V-132
350-V-022
350-C-052
350-XOV-021

Pressure drop (bar)

0.0201153
0.0201153
0.0358043
0.298508

Tab. 1. Valves pressure drops at 2000 m3/h based on Flowmaster component

database.

Pressure drops across oil metering skid are based on data presented on page
6 of document OFFLOADING HOSE LENGTH AND HYDRAULIC
CALCULATION TECHNICAL NOTE and are presented in Fig. 7.

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Fig. 7. Oil metering skid pressure drops as a function of oil flow rate.
Add basis/assumption for
hose/riser elevation i.e. from
topsides to bottom of riser

Hose properties are based on documents REF#4 THHE - Caratteristiche Tubi

- 22-06-2015.xlsx and REF#9 LFPSO-H100000271-1-C01-00001 Rev00.pdf. In particular the length of the hose between point C and MBC
(MIBreak 12) is 239.4 m while the length of the hose between MBC and point
D is 44.9 m.

The operating conditions are 30 C at atmospheric pressure (1.0132 bar).

Crude oil physical properties at these conditions are reported in

Tab. 2. Density and viscosity are computed as the average values of the ten
samples presented in document REF#3 Reference1 oil samples.xlsx.
Saturation pressure is the average value between minimum and maximum
values provided in document Data required for Pressure Surge Analysis from THHE - Engi Soft.docx. Bulk modulus is derived from the API gravity of
the values provided in document Data required for Pressure Surge Analysis from THHE - Engi Soft.docx. Again the average values of the ten samples
provided is considered.

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Mass Density
Viscosity
Saturation Pressure
Bulk Modulus

kg/m3
Pa s
bar
GPa

772.8714935
0.001520114
0.83295
1.104029831

Tab. 2. Crude oil physical properties at 30 C and atmospheric pressure (1.0132

bar).
A steady state analysis is performed, in which a flow rate of 2000 m3/h is imposed at
the pump together with a pressure of 1.55 barg at its suction, to obtain a pressure of
3.1 barg at point D, as specified. Simulation results are presented in
Tab. 3 and compared with provided data.

Pump Rot. Speed (rpm)

Pump Flow Rate (m3/h)
Pump Head (m)
Pressure@A (barg)
Pressure@D (barg)
Pressure Drop@Oil Metering (bar)
Pressure Drop@Check Valve (bar)
Pressure Drop@Hose (bar)
Pressure Drop@Section AD (bar)

Data
1500
2000
130.8
11.34
3.1
0.845
0.036
4.574
8.240

Results
1500
1999.98
130.79
11.46
3.1
0.845
0.036
4.556
8.364

Difference (%)
0.000%
-0.001%
-0.004%
1.097%
0.000%
-0.006%
-0.021%
-0.384%
1.510%

Tab. 3. Results of the steady state analysis are compared with provided data.

In tab. 4 the resulting inlet boundary conditions for the MIBreak unit are presented.
Inlet Total Pressure
Inlet Static Pressure
Inlet Velocity
Inlet Mass Flow Rate
Inlet Volumetric Flow Rate

Pa
Pa
m/s
kg/s
m3/s

Tab. 4. Results at MIBreak inlet.

592218
569432
7.654
429
0.556

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3.

PETALS CLOSURE SEQUENCE

When the break load is reached, the MIBreak unit is activated to separate and petals
close with the sequence here below described.
In the first open configuration petals are covered by the internal sleeve, where oil can
freely flow. As the HBU starts closing, the large petals close immediately while the
small petals closure is slowed down by the hydraulic dampening system. See the
sequence in the table below, where the rotation angle is considered starting from the
closed position.

Pos.

Petal angle
Large
Small

Pos.
1

60

60

Pos.
2

60

Pos.
3

50

Pos.
4

40

Pos.
5

30

Petals Configuration

Fully open.
Petals are covered.

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Pos.
6

20

Pos.
7

10

Tab. 5. Petals closure sequence.

4.

SURGE ANALYSIS

Closure of the MIBreaks upstream petal valve against the flow is simulated in order
to calculate the minimum closure time that produces a peak of pressure lower than
25.3 bar, i.e. 1.33 x design pressure that is 19 bar.
The calculated closure time corresponds to a defined geometry of the is correlated
with the geometry of the dampening system.
The wave speed a is computed by the relation:

Where is the liquid density (kg/m3), k the bulk modulus of liquid (N/m2), d the pipe
internal diameter (m), t the pipe thickness (m), E the Young's Modulus of pipe
material (N/m2) and the pipe restraint factor (usually set equal to 1). A wave speed
of 220 m/s is considered for the flexible hose while a wave speed of 1115 m/s is
considered for the steel pipes.

Please add ref for

wave speed
assumption

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Fig. 8. Surge analysis - Small petal angle Vs. Time.

Fig. 9. Surge analysis - HBU closure Vs. Time

(1 represents fully open HBU, 0 representes fully closed HBU).

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Clarify point for this pressure

Is the description correct?

Believe steady state pressure
at upstream of MBU should be
higher than downstream of
check valve due to positive
elevation diff. Please check
and confirm ie. red should be
downstream check valve and
blue should be upstream of
clarify point for this pressure?

MBU.

Fig. 10. Surge analysis - Pressures upstream of the HBU (red) and downstream
of the check valve (blue).

A computed maximum pressure of 25.04 barg occurs upstream of the HBU with a
closure time of 5.4 sec. Another point of high pressure is downstream of the check
valve where the pressure reaches the maximum value of 24.14 barg. In Fig. 10
pressures at these two points are presented.
this shall be reduced to
below 24barg.

5.

FUNCTIONAL TEST

As explained in the introduction, an additional analysis is performed to simulate the

functional test during the FAT, when the closure time will be checked without any
flow at ambient temperature (20 C assumed in the analysis).
With the geometry of the dampening system defined as result of the surge analysis,
the corresponding computed closure time of the petals during the functional test,
when there is no load from the flow acting on the petals and the petals are forced to
close only by the springs of the mechanism, is 21.8 s. The small petal angle variation
as a function of time is presented in Fig. 11. This corresponds to the HBU closure
presented in Fig. 12.

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Fig. 11. Functional test - Small petal angle Vs. Time.

Fig. 12. Functional test - HBU closure Vs. Time

(1 represents fully open HBU, 0 representes fully closed HBU).

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6.

CONCLUSIONS

This surge analysis defines the ideal closure time for the MIBreak unit in order to
avoid a water hammer effect higher than 1.33 times the design pressure.
The needed closure time results 5.4 sec in the operating condition of the transfer line.
This defines the geometry of the dampening system that when subjected to
functional test in empty condition gives a closure time of 21.8 sec. This is the
characteristic value for this MIBreak unit, that will be checked in the Factory
Acceptance Test.