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Simplified Technique for Predicting Offshore Pipeline Expansion

更新时间:2016-07-05

1 Introduction

For the deepwater development of oil and gas production,it is well recognized that the effect of severe environmental conditions,i.e.,high pressure and high temperature(HPHT),has caused various difficulties.Recently,several researches have proposed designs for robust offshore and subsea structures that can withstand the abovementioned problems.In HPHT conditions,thermal expansion naturally occurs in structures such as pipelines,subsea systems,and topside facilities.Therefore,engineers must carefully design and confirm the robustness of offshore oil and gas production structures.This is especially true for subsea structures that are difficult to repair and/or replace in response to the occurrence of unexpected problems,the cost of which is much greater than those of onshore or nearshore cases.

To overcome HPHT-related problems of subsea pipelines,i.e.,thermal expansion and global and local buckling,engineers must consider the amount of thermal expansion that may take place.In this regard,numerous studies have been conducted related to the expansion of pipeline in terms of singlewall cases(Palmer and Ling 1981;AGA 1987;Hobbs and Liang 1989;Choi 1995)and pipe-in-pipe(PIP)cases(Choi 2002;Kershenbaum et al.1996;Harrison et al.1997),as well asmany others.Recently,Baiand Bai(2014)widely reviewed and summarized existing methods for the thermal expansion design of subsea pipelines.In real subsea pipeline projects,engineers design the pipeline based on DNV(2011,2013)and API(2015)design codes that establish engineering design standards based on mechanical theories.Furthermore,many kinds of expansion problems,especially those related to HPHT conditions,were addressed in the joint industry project(JIP)SAFEBUCK,which considered the design challenges for pipelines.In addition,the analyses of pipeline expansion extend to structures attached at the end of the pipelines,including risers,manifolds,and pipeline end terminals(PLETs).

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Estimations of subsea pipeline expansion are calculated using complex equations and diverse variables,so equations that have been developed based on experience could be simplified for the purposes of structural design at the initial engineering stages(pre-front-end engineering design(Pre-FEED)and FEED).In this study,we found the relationship between the virtual anchor length and the SDR to be exponentially proportional under conditions in which other variables are fixed.On this basis,we propose a simple and reliable diagram,shown as an exponential equation that can easily calculate the pipe expansion length by changing some of the input values.The insights developed in this study will be useful for engineers who are designing and installing subsea pipelines.

2 Method for Expansion Analysis

Before describing our expansion analysis procedure,first,we clearly define the term subsea pipeline expansion.A pipeline is usually installed at the same temperature as the surrounding environment,in this case,the seawater temperature.However,upon becoming operational,the inlet temperature dramatically increases so the temperature of the whole line also changes.At the same time,the pipeline is also pressurized.The expansion of subsea pipeline is related to the increment of difference between the temperature and pressure and is closely related to the global buckling design procedure shown in Fig.1.In this study,we addressed the whole procedure,from “Start” to the“calculation of expansion length” of the subsea pipeline.

It is well recognized that subsea structures must function safely throughout their design life.Generally,if any problem is encountered in the operation of subsea structures,their oil and gas productions should be stopped and inspection and repair processes undertaken.However,it is not easy to undertake repair work.Whereas ship structures can be dry docked(or re-docked)for the purposes of repair and periodic surveys for status monitoring,the suspension of oil and gas production entails great expense and time,which means substantial loss of income.In this regard,subsea pipeline engineering design,installation,and operation must be reliable and must take advantage of proven high-technology solutions.

Fig.1 Overview of global buckling design considering pipe expansion

Currently,the terminologies used in Fig.2 are widely employed in expansion analyses of subsea pipelines(Choi et al.2008).The free expansion analysis case is defined as occurring when the pipe end restraining forces are zero,but the pipe strain at the end is not.Anchor points(Nes et al.1996)are the fixed points presented in Fig.2,where pipe movement due to expansion is stopped.The pipeline portion from the free end to the anchor point is defined as the unrestrained zone.Lastly,the fully restrained zone is the portion between the anchor points.Predicting the position of the anchor points can help guide the formulation of the subsea pipeline route that will minimize and avoid structural problems,especially lateral buckling.

Fig.2 Overview of subsea pipeline expansion and terms(Choi et al.2008)

Strain due to end cap effect(pressure effect)

In this study,we analyzed pipeline expansion with the assumption of free expansion with uniform temperature.This means that we assumed zero restraining forces at the pipe end,but soil friction along the pipe.In this case,the interaction forces at each upper and lower position are zero,as shown in Fig.2.This is called a free expansion problem in which we also assume the temperature difference between the product and environment to be constant along the pipeline.We define the anchor points in Fig.2 as the two points where movement is zero.The anchor lengths at each end side,i.e.,Lu and Ld,are called the moving portions,which include the space from the pipe end to the anchor point.As shown in Fig.2,these two values will be similar due to the constant temperature.Finally,we define the portion in between the anchor points as the fully restrained zone.

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Strain due to mobilization of soil friction

Strain due to residual lay tension

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3 Applied Examples

Using the procedures mentioned in Section 2,in this section,we describe the application studies we conducted using reliable scenarios.Lastly,we propose the use of the SDR versus virtual anchor length diagrams that are derived from the conventional equations.

3.1 Definition of Design Inputs

3.1.1 Structural Characteristics

In general,we adopted outer diameters ranging from 8 to 14 in.to represent flow lines that are especially subject to HPHT fluids from oil wells.To represent reasonable cases,we defined a wall thickness range that satisfies the requirement for a long pipeline(LA<L total/2)at structural specifications and environmental conditions.Table 1 summarizes the structural characteristics that cover the geometric,mechanical,and material properties.

As presented in Fig.1,if we can apply time-dependent corrosion damage to these pipeline structures,then we can generate accurate and realistic outcomes.The first time dependent corrosion model was proposed by Paik et al.(2003a,b)for tanker/FPSO and bulk carrier structures,respectively.Since then,those corrosion models have been applied by Kim et al.(2012a,b,2014,2015)in the assessment of corrosion conditions of damaged ship structures.Recently,an advanced technique for the development of time-dependent corrosion models was proposed by Paik and Kim(2012)and was then applied to subsea pipeline structures(Mohd Hairil et al.2014).In our study,we selected 100 cases based on a pipe-wall thickness that ranged from 15 to 28 mm for each outer pipeline diameter.We then divided this thickness range into 100 sub-ranges.

3.1.2 Environmental Parameters

The calculation of the virtual anchor length is perform ed in steps 1 and 2,which were presented in Sections 3.1 and 3.2.Figure 3a-e shows the obtained SDR versus LA diagrams.In this paper,we applied five different pressure cases.In addition,each case consists of four sub-cases,which we applied in different temperature conditions.

Table 1 Structural data

API-X65 and 70 are considered as structural data

Type Data Pipe outer diameter/in. 8,10,12,14 Pipe-wall thickness/mm 15-28 Density of steel pipe/(kg m-3) 7850 Poisson’s ratio 0.3 Young’s modulus/GPa 207 Thermal expansion coefficient(1/°C) 1.171 × 10-5 Total installed pipe length/km 100

Table 2 Properties of production fluid and environmental data

Type Data Density of production fluid/(kg m-3) 90 Temperature difference/°C—5 cases 30 to 150 Pressure difference/MPa—5 cases 10 to 90 Water depth/m 1000 Seawater density/(kg m-3) 1025 Friction coefficient of soil 0.6

3.2 Definition of Expansion Parameters

The parameters causing expansion of subsea pipelines can be classified into five components,i.e.,the Poisson effect,thermal effect,pressure effect,soil friction effect,and residual lay tension effect.In this section,we describe these factors in detail.In this study,we derived all the processes using the strain-based approach.The total strain,called the net strain,can be obtained by combining all the parameters,as shown in

Fig.3 LA Calculation results for case 3.a Case 3-1:10 MPa.b Case 3-2:30 MPa.c Case 3-3:50 MPa.d Case 3-4:70 MPa.e Case 3-5:90 MPa

Table 3 Virtual anchor length exponential function information(LA/L= α ⋅e(OD/t)β)

Press./MPa Temp./°C Case 1:OD=8 in. Case 2:OD=10 in. Case 3:OD=12 in. Case 4:OD=14 in.αβR2αβR2αβR2αβR2 10 30 0.01379 0.04477 0.9987 0.01315 0.05241 0.9974 0.01249 0.05784 0.9966 0.01187 0.06197 0.9949 60 0.02920 0.04241 0.9985 0.02770 0.04864 0.9969 0.02620 0.05348 0.9959 0.02482 0.05744 0.9938 90 0.04461 0.04165 0.9984 0.04227 0.04738 0.9967 0.03994 0.05199 0.9956 0.03782 0.05887 0.9934 120 0.06003 0.04128 0.9984 0.05885 0.04675 0.9966 0.05370 0.05123 0.9954 0.05083 0.05506 0.9932 150 0.75442 0.04106 0.9984 0.07143 0.04637 0.9965 0.06746 0.05078 0.9954 0.06384 0.05458 0.9931 30 30 0.01164 0.06931 0.9998 0.01146 0.07388 0.9994 0.01115 0.07741 0.9990 0.01076 0.08039 0.9982 60 0.02670 0.05515 0.9993 0.02554 0.06055 0.9984 0.02433 0.06483 0.9976 0.02317 0.06842 0.9963 90 0.04198 0.05025 0.9990 0.03993 0.05561 0.9978 0.03785 0.05996 0.9969 0.03593 0.06366 0.9953 120 0.05732 0.04777 0.9989 0.05440 0.05304 0.9975 0.05148 0.05738 0.9965 0.04880 0.06111 0.9947 150 0.07270 0.04627 0.9988 0.06891 0.05146 0.9973 0.06516 0.05578 0.9983 0.06173 0.05951 0.9943 50 30 0.01023 0.08918 0.9999 0.01051 0.08989 0.9999 0.01053 0.09125 0.9998 0.01035 0.09296 0.9994 60 0.02469 0.06655 0.9997 0.02396 0.07068 0.9992 0.02308 0.07416 0.9987 0.02214 0.07723 0.9978 90 0.03971 0.05823 0.9994 0.03803 0.06297 0.9986 0.03626 0.06892 0.9979 0.03455 0.07034 0.9966 120 0.05491 0.05391 0.9992 0.05232 0.05881 0.9982 0.04968 0.06291 0.9974 0.04721 0.06647 0.9959 150 0.07019 0.05125 0.9990 0.06671 0.05621 0.9979 0.06322 0.06037 0.9970 0.05999 0.06399 0.9953 70 30 0.00925 0.10570 0.9995 0.00995 0.10237 0.9997 0.01026 0.10161 0.9999 0.01026 0.10213 0.9999 60 0.02306 0.07684 0.9999 0.02278 0.07943 0.9997 0.02222 0.08199 0.9994 0.02150 0.08447 0.9987 90 0.03775 0.06566 0.9997 0.03648 0.06961 0.9992 0.03503 0.07305 0.9986 0.03355 0.07614 0.9976 120 0.05275 0.05971 0.9994 0.05054 0.06414 0.9987 0.04820 0.06793 0.9980 0.04595 0.07127 0.9968 150 0.06790 0.05602 0.9993 0.06477 0.06065 0.9984 0.06157 0.06460 0.9976 0.05855 0.06807 0.9962 90 30 0.00853 0.11972 0.9987 0.00960 0.11242 0.9992 0.01018 0.10968 0.9997 0.01035 0.10915 0.9998 60 0.02171 0.08619 0.9999 0.02187 0.08708 0.9999 0.03407 0.07850 0.9991 0.02112 0.09056 0.9993 90 0.03604 0.07260 0.9999 0.03520 0.07563 0.9995 0.04698 0.07249 0.9986 0.03281 0.08122 0.9983 120 0.05080 0.06522 0.9997 0.04901 0.06907 0.9991 0.06015 0.06852 0.9981 0.04496 0.07558 0.9975 150 0.06580 0.06058 0.9995 0.06306 0.06483 0.9988 0.21627 0.08866 0.9997 0.05736 0.07181 0.9969

Fig.4 Proposed method for estimating pipe expansion length using the LA diagram

Eq.(4).The five parameters can be individually expressed using Eqs.(5.1)to(5.5),respectively.

In general,five types of conditions,i.e.,free expansion with uniform temperature,free expansion with temperature gradient,expansion with end restraints,expansion of pipe-in pipe system,and lateral deviation(so-called snaking),are considered when estimating the expansion of subsea pipelines,which have been widely reviewed by Choi et al.(2008)and Bai and Bai(2014).

Strain due to the Poisson effect

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Strain due to thermal effect

A more advanced pipeline expansion calculation method,i.e.,free expansion with a temperature gradient and expansion with temperature gradient,can be found in the paper by Choi et al.(2008).

In this section,we address the calculation of the virtual anchor length(LA)based on Eq.(6).The procedure for developing the diagram,including the required input data and output,can be summarized as follows:

Fig.5 Exponential function indices.a Index(α).b Index(β)

The force equilibrium in the pipeline can be expressed as shown in Eq.(1).The virtual anchor length can be derived once Eq.(1)is solved,as shown in Eq.(2)(Choi et al.2008).The expansion of the pipeline with a free-end condition can be calculated using Eq.(3).

After calculating the total strain of the subsea pipeline,we can estimate the virtual anchor length(LA).Generally,the virtual anchor length is obtained using Eq.(6).Finally,integrating the total strain gives the pipeline expansion length,as shown in Eq.(7).

3.3 Calculation of Virtual Anchor Length

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·Step 1:Definition of design input(structural and environmental parameters)

·Step 2:Definition of expansion parameters(Poisson ratio,thermal,pressure,soil friction,residual laying tension)

·Step 3:Calculation of expansion length

·Step 4:Development of SDR versus LA diagram

·Step 5:Investigation of exponential function indices(α and β)

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We assumed deepwater environmental conditions,for which the properties of the seawater,seabed,and production fluid,for example,must be defined.The pressure and temperature difference properties refer to the different conditions between the production fluid and the environment,so we omitted some product and environmental properties with respect to the temperature and pressure conditions.Table 2 show s theproduction fluid properties and the environmental conditions surrounding the subsea pipeline.

Figure 3 shows the virtual anchor length calculation results for a pipe 12 in.in diameter.Based on these results,we can develop the empirical formula using the curves mentioned in step 5 and Eq.(8).Then,we can define the obtained empirical formula as the SDR versus anchor length diagram.We can determine the linear trend by the exponential function indices and the pipe diameter based on the coefficient of determination(R2).

where α and β can be defined as exponential function indices.

Table 3 lists the exponential function information derived from all the expansion analysis cases for the virtual anchor length.

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3.4 Estimation of Pipeline Expansion Length by Developed Diagrams

We propose a new method for estimating the virtual anchor length of subsea pipelines and investigate its potential applicability to various diameters and wall thicknesses.In this section,we offer guidelines for applying the SDR and LA diagram,as illustrated in Fig.4.

Fig.6 Index functions forαandβexponential functions shown in Fig.5.a α-power function index aα.b α-power function index bα.c βpolynomial function index aβ.d β-polynomial function index bβ.e βpolynomial function index cβ

Table 4 Verification test case data

Type Data Pipeline diameter/in. 10 Wall thickness/mm 20,25,30 Temperature difference/°C 60,90,120 Pressure difference/MPa 30,50,70

When the structural and environmental characteristics have been defined,two types of exponential function indices(α,β)are then selected based on the developed chart shown in Fig.4.In the previous section,we showed several charts for selecting exponential function indices to verify the proposed method.These obtained charts for the exponential function indices seem sufficient for their application in estimating the expansion of subsea pipelines.However,there are also some limitations regarding the estimation of each index.

To determine the two types of exponential function indices,we use new specific relations between the pressure and temperature differences to obtain the appropriate equations.These two specific relations are expressed as shown in Eqs.(9)and(10):

Finally,Fig.5 shows the relation between the exponential function indices,for which we considered a total of 100 test cases,and the new specific variables.Once we have determined the exponential function indices,we can develop the empirical formula(step 4)using Eq.(8),which contains both the exponential function indices(α,β),and the SDR.

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Furthermore,the indices and variables,which are composed of the exponential function indices,are directly related to the pipeline OD and this relation is illustrated in Fig.6.

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According to the experiential equations derived above,we obtain five variables(aα,bα,aβ,bβ,and cβ)for the power function indices and the polynomial function variables with OD values in Eqs.(11)and(12),and those relationships are shown in Fig.6.Using the diagrams shown in Figs.5 and 6,we can estimate the indices of the virtual anchor length equation.

Briefly,under variable operating conditions and diverse pipeline sizes,we can derive the functions for the virtual anchor length by the expansion analysis shown in Fig.3,which shows the exponential proportional relationship between the SDR and LA.By using the functions in Eqs.(8)to(12)for the outer diameter,wall thickness,and pressure and temperature differences,engineers can easily determine the virtual anchor length,which makes it possible to estimate the pipeline expansion length.

4 Verification o f Simplified Virtual Anchor Length Equation

Fig.7 Test case comparison results.a ΔT=90 °C.b ΔP=50 MPa

We verified the diagrams proposed before the steps and simplified exponential equations for several cases against the conventional calculation results obtained using Eqs.(2)and(3).We determined the expansion length using the proposed method as the exponential function for the virtual anchor length,which we put into Eq.(3).Table 4 shows the selected cases used to verify the proposed method,as compared with the results shown in Fig.7.

According to Fig.7,the proposed method has minor errors in comparison with the analytical solution.To determine there as on for these errors,we fixed or changed the parameters such as pressure and temperature differences with respect to the SDR,the results of which are shown in Tables 5 and 6,respectively.

In Tables 5 and 6,for the specific reliable environmental,structural,and operating conditions described in Tables 1 and 2,the expansion lengths determined using the proposed method are almost the same as those by the analytical method shown in Fig.7.The coefficient of variation(COV)values are also very small,ranging from orders of 10-4 to 10-2,which means that the proposed diagram approaches may be considered reliable.

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5 Concluding Remarks

In this study,we developed useful diagrams for estimating the virtual anchor length,which makes it possible to determine the expansion length of subsea pipelines.We verified the applicability of this approach by using example cases.The purpose of this study was to propose a method for generating easy,accurate,and efficient diagrams for predicting the expansion length of subsea pipelines.To illustrate the expansion length,we adopted four representative cases of outer pipeline diameters and 25 sub-cases.Once we have determined the pipeline diameter and differences in the temperature and pressure,we can directly calculate the exponential function indices(α,β).Once we have determined these two variables,we can easily obtain the expanded length of subsea pipelines using simple exponential equations and the net strain value.

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Despite our consideration in this study of diverse combinations of pressure and temperature under reliable environmental conditions,the applicability of our proposed expansion estimation method is rather limited in that we could not include the length of the pipeline as a factor.However,the development of pipe expansion length estimation methods is worthwhile as it shows that the amount of pipeline expansion can be simply determined as a function of pressure,temperature,and pipe dimensions.In further analyses that include various pipeline lengths as a factor,we will develop a universal diagram for predicting the expansion length of pipelines.

Based on our results,we can conclude that our proposed method will be useful for estimating the expansion length of subsea pipeline structures by changing the dimensional inputs under similar conditions.The proposed method may also be employed to determine the number of spool or bend systems based on the obtained expansion length.In addition,it can be used to develop acceptance criteria for structural buckling behavior of installed subsea pipelines.

Acknowledgements This study was undertaken at Ocean and Ship Technology(OST)under Deepwater Technology Mission Oriented Research at Universiti Teknologi PETRONAS.This research was supported by the Technology Innovation Program(Grant No.:10053121 and 10051279)funded by the Ministry of Trade,Industry,and Energy(M I,Korea)and YUTP Grant(0153AA-E60,Malaysia).The authors would also like to thank for the great support of POSTECH,POSCO,and Daewoo E&C,Republic of Korea.Some part of this paper was presented in The 3rd International Conference on Civil,Offshore and Environmental Engineering(ICCOEE 2016),15-17 August,Kuala Lumpur,Malaysia.

随着全面深化改革不断推进,一系列的“政策套餐”,极大地增强了云南省民营经济和中小企业发展的动力和活力。

Foundation Item Supported by the Technology Innovation Program(Grant No.:10053121 and 10051279)funded by the Ministry of Trade,Industry&Energy(M I,Korea).

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J.H.Seo,D.K.Kim,H.S.Choi,S.Y.Yu,K.S.Park
《Journal of Marine Science and Application》2018年第1期文献

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