JOB NO. DOC. NO. REV.

A
DATE: SHEET : 1 OF 8

PREP’D BY
CHK’D BY
APP’D BY

PIPELINE ENGINEERING

WALL THICKNESS and BUCKLING CALCULATION CHECK

JOB PERTAMINA – PETROCHINA EAST JAVA.

REV DATE PAGES DESCRIPTION PREP’D CHK’D APP’D COMPANY

A ALL ISSUED FOR REVIEW

JOB PERTAMINA-PETROCHINA EAST JAVA

TABLE OF CONTENT
Cover ............................................................................................................................... .1
Table of Content ............................................................................................................. .2
1. Scope.................................................................................................................... .3
1.1 Project Description ..............................................................................................................................3
1.2 Objectives ............................................................................................................................................3
2. References ........................................................................................................... .3
3. Pipeline Design Parameters ................................................................................ 4
3.1 List Of Primary Coordinate Of The Pipeline Route.............................................................................4
3.2 Pipeline Design Life ............................................................................................................................4
3.3 Pipeline Design Factors .......................................................................................................................4
3.4 Exposure Condition .............................................................................................................................4
3.5 Environmental Data .............................................................................................................................4
3.6 Seawater Properties..............................................................................................................................4
3.7 Functional Parameters..........................................................................................................................5
3.8 Material Properties...............................................................................................................................5
4. Design Requirements........................................................................................... 5
4.1 Wall Thickness Calculation .................................................................................................................5
4.1.1 General .................................................................................................................................. 5
4.1.2 Hoop Stress............................................................................................................................ 6
4.1.3 Buckle Propagation ............................................................................................................... 5
4.1.4 Buckle Initiation .................................................................................................................... 7
4.1.5 Pipe Collapse......................................................................................................................... 7
4.1.6 Summary ............................................................................................................................... 8

Attachment
Attachment 2 Wall Thickness Calculation Spreadsheet

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JOB PERTAMINA-PETROCHINA EAST JAVA

1. Scope
1.1 Project Description
Recently JOB Pertamina –Petrochina East Java has been operating 10” diameter subsea
pipeline extending from palang station located at Tuban seaside, to FSO Cinta Natomas
located at Java Sea 22 km northern of Tuban. The pipeline has now been operated at
maximum flow capacity of 60.000 BOPD, whereas the production forecast snows that
the increase of the production will be continue until 2011. Many alternative solutions
have been studied, the additional pipeline installation will be the best option.

Therefore, Company intend to have additional 10” diameter subsea pipeline 22 km long
from Palang to Station FSO Cinta Natomas. The proposed pipeline can be started from
offshore initiation point and onshore point then goes pararel with existing 10” diameter
pipeline. The proposed pipeline will pass inter tidal crossing at palang then goest
further northern to sea using the existing ROW. The engineering scope of work based
on EPCI contract. The SOW will be divided into the following:
• Pipeline Engineering Design and Installation
• New PLEM design, Fabrication and Installation
• SPM Piping Modification

1.2 Objectives
This report covers pipeline wall thickness calculation check of the new 10” diameter
pipeline. The wall thickness criteria are hoop stress, collapse, initiation buckling, and
propagation buckling analysis. The Analysis is carried out for installation and operation
loading condition.

2. References
A. ASME B31.4
B. API RP 1111, Design, Construction, Operation and Maintenance of Offshore Hydrocarbon
Pipelines, 2nd Edition 1993.
C. API 5L, Specification for Line Pipe, 2000 Edition.
D. DNV OS F101, Rules for Submarine Pipeline System, 2000 Edition.
E. DNV 1981, Rules for Submarine Pipeline System.

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JOB PERTAMINA-PETROCHINA EAST JAVA

3. Pipeline Design Parameters

3.1 List of Primary Coordinate of The Pipeline Route
The list of primary coordinates of the pipeline route is given in table 3.1.1.
Table 3.1.1 Primary Coordinate of The Pipeline Route
Location Latitude Longitude Northing Easting
SPM and PLEM 6° 40' 15" S 112° 09' 33" E 9 263 279.5 N 712 152.0 E

3.2 Pipeline Design Life

The design life for the pipeline system is 20 years [Ref. H].

3.3 Pipeline Design Factors

Design factors used for the analysis of the pipeline are shown in table 3.3.1.

Table 3.3.1 Design Factor [Ref. A].

Description Zone 1 Zone 2
Wall Thickness
Design Factor 0.72 0.5

3.4 Exposure Condition

Pipeline installation at water depth more than 13 meters will be exposed to seawater
while the remaining portion which is installed at water depth less than 13 meters will be
buried under seabed. Table shown below presents the pipeline exposure condition:

3.5 Environmental Data

The water depth along the pipeline route considers Mean Sea Level (M.S.L.), Highest
Astronomical Tide (H.A.T), 1-year storm surge and 100-year storm surge.
Table 3.5.1 Water Depth Data
Description Unit Value
Water Depth
Max. [Ref. K] m 25
Min. [Ref. K] m 0.0
Lowest Astronomical Tide (L.A.T.) [Ref. L] m -1.18
Highest Astronomical Tide (H.A.T) [Ref. L] m +1.098
1 Year Storm Surge [Ref. J] m 4.9
100 Years Storm Surge [Ref. J] m 8.5

3.6 Sea Water Properties

Table 3.6.1 Sea Water Properties [Ref. H]
Description Unit Value
Density of Sea Water kg/m3 1025
o
Max. Sea Floor Temperature C 28.9
o
Min. Sea Floor Temperature C 15
Kinematics Viscosity m2/s 9.6E-7

3.7 Functional Parameters

Table 3.7.1 Functional Parameters [Ref. H]
Description Unit Value

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JOB PERTAMINA-PETROCHINA EAST JAVA

Description Unit Value

Pipeline Size Inch 10.75
ANSI Flange Class # 600
Design Pressure, at 200 oF Psig. 1350
Hydrotest Pressure Psig. 1688
o
Design Temperature F 200
Content Density kg/m3 48.944

3.8 Material Properties

Table 3.8.1 Material Properties [Ref. H]
Description Unit Value
Material - API 5L Gr. X-52
Specified Minimum Yield Strength Psi. 52,000
Steel Density kg/m3 7850
Young Modulus MPa 207000
Thermal Expansion Coefficient 1/oC 1.17E-5
Poisson Ratio - 0.3

4. Design Requirements
4.1 Wall Thickness Calculation
4.1.1 General
The nominal wall thickness (tnom) is the sum of the minimum design wall
thickness (tmin), a corrosion allowance (tcorr), and a manufacturing tolerance
(tfab).

t nom = t min + t corr + t fab

The design thickness used will vary depending on the phase, i.e. t = tmin for
operating condition, and t = tmin + tcorr for the testing phase. The engineer
should take account of the the lifecycle conditions which may cause a wall
thickness reduction through the design life of the pipeline.

The corrosion allowance is applied to pipelines operating in a corrosive

environment, the corrosion allowances may be either internal and/or external.
The requirement for the corrosion allowance varies between codes (refer to
Section Error! Reference source not found.).

The manufacturing tolerance is required to account for the variations in wall

thickness that occur during fabrication. These tolerances generally comply with
API 5L unless it is expressly specified otherwise.

Where the nominal thickness varies from the standard production pipe
thicknesses then economics may dictate a thicker section than necessary be used
to match the commercially available wall thicknesses.

4.1.2 Hoop Stress

The DnV code includes the external pressure in the hoop stress calculation. It
also uses the median diameter, i.e. the average between the Internal and external
diameters [Section 5 B211].

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JOB PERTAMINA-PETROCHINA EAST JAVA

(D − t)
σ h = ( Pi − Pe )
2t
where:
σh = hoop stress
Pi = internal design pressure
Pe = external design pressure
D = external diameter
t = wall thickness

DnV approach applies the following limits to the hoop stress [Section 5 C203 &
C204].

Yielding Limit State σh ≤ ηsSMYS

Ultimte or Bursting Limit State σh ≤ ηuSMTS

where:
ηs, ηu = load factor
SMYS = minimum specified yield strength
SMTS = minimum specified tensile strength

Load Factor Safety Class Pressure Test

Low Normal High
ηs 0.83 0.77 0.77 0.96
ηu 0.72 0.67 0.64 0.84
Table 4.1 - Internal Pressure Design Load Factor specified by DnV 96

The DnV code also allows higher load factors to be used when certain criteria are met [section 5 C205]

4.1.3 Buckle Propagation

The DnV approach for external pressure collapse is as follows [Section 5 C306]:

(P col ( )
− Pcr ) Pcol 2 − Ppl 2 = Pcol Pcr PplU 0
D
t
where:
Pcr, D, t = As defined above
Pcol = As defined above with the following condition
Pcr
≤ [Section 5 C310, C311, & C312]
.γR
11
U0 = as defined above with 0.5% ≤ U0 ≤ 3% [Section 5 C306 & C800]
Ppl = Plastic collapse pressure
= 2σ y t
D

4.1.4 Buckle Initiation

The minimum wall thickness for buckle initiation is calculated as per API RP
1111 [Ref. B]. The formula used for the calculation is the same with buckle

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JOB PERTAMINA-PETROCHINA EAST JAVA

propagation but with taking the initiating buckle pressure equal to 1.25 times the
propagating pressure.

4.1.5 Pipe Collapse

The DnV code has two separate design cases for the combined loading
consideration, load-controlled conditions and displacement-controlled
conditions. A load -controlled condition is characterised by loads that are
independent of displacement, and displacement controlled condition is
characterised by displacements that are independent of load. The load-controlled
condition check can always be applied as it is more conservative than the
displacement-controlled condition. [section 5 C100]

The combined loading checks are defined as follows [section 5 C305]

Load-Controlled condition:
2 2
   
γ γ M +γ M   
 F C F ,c E ,c  Pe
+  ≤1
E

 Mc   Pc 
   
 γR  γR 

Displacement-Controlled condition:
0.8
 
 
 γ F γ C ε F ,c + γ E ε E ,c  +
Pe
≤1
 ε M ,c  Pc
 
 γε  γR

where:
MF,c = characteristic functional bending moment
ME,c = characteristic environmental bending moment
Mc = characteristic limit bending moment [section 5 C307]
γF = function load factor
γE = environmental load factor
γC = condition load factor
γR = strength resistance factor
Pe = characteristic external over pressure
Pc = characteristic collapse pressure [section 5 C306]
εF,c = characteristic function longitudinal strain
εE,c = characteristic environmental longitudinal strain
εM,c = characteristic buckling strain capacity [section 5 C308]
γε = strain capacity resistance factor

4.1.6 Summary
In order to fulfill the requirements, minimum nominal wall thickness will be
taken as the following:

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JOB PERTAMINA-PETROCHINA EAST JAVA

• Kp. 0.0 to Kp. 22 : 0.5 in wall thickness

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 ATTACHMENT

Wall Thickness Calculation Spreadsheet