QUSAHWIRA FULL FIELD DEVELOPMENT PROJECT ADCO PROJECT No. P-14364

ADCO CONTRACT NO.: 7278.01/EC 10737 NPCC PROJECT No.: 9063

SPECIFICATION FOR PIPING FLEXIBILITY ANALYSIS

ADCO DOCUMENT No.: 58.99.08.1606

THIS DOCUMENT IS DEVELOPED FROM FEED DOC. NO. 30.78.12.0669 REV C PROJECT NO. P14364

I 23-NOV-2010 BS VS AS Issued For IDC

REV. DATE ORIGINATOR REVIEWED APPROVED DESCRIPTION

THIS DOCUMENT IS INTENDED FOR USE BY ADCO AND ITS NOMINATED CONSULTANTS, CONTRACTORS, MANUFACTURERS AND SUPPLIERS.

EPC CONTRACTOR: NATIONAL PETROLEUM CONSTRUCTION COMPANY P.O. BOX 2058, ABU DHABI, UNITED ARAB EMIRATES

____________________________________________________________________

ENGINEER: ENGINEERS INDIA LIMITED , NEW DELHI, INDIA

ADCO DOC. No. 58.99.08.1606 CONTRACTOR DOC No.: A049-000-16-43-SP-0010 PAGE: 1 OF 30

DOCUMENT TITLE: SPECIFICATION FOR PIPING FLEXIBILITY ANALYSIS

PROJECT No. :P 14364

ADCO DOC.No.: 58.99.08.1606

REV I DATE: 23-NOV-2010

CONTRACTOR DOC. No. A049-000-16-43-SP-0010 PAGE: 2 OF 30

TABLE OF CONTENTS

1.0 INTRODUCTION ……………………………………………………………………….5 1.1 Project introduction ………………………………………………...5 1.2 Project scope ………………………………………………………….6

2.0 PURPOSE & SCOPE……………………………………………………………………7 3.0 REFEREENCES…………………………………………………………………………7 3.1 Document Precedence ……………………………………………...8 4.0 APPLICABLE CODES AND STANDARDS……………………………………….....8 4.1 Codes, Standards and Regulations ……………………………..8 4.2 Definitions …………………………………………………………..9 4.3 Abbreviations……………………………………………………………9 5.0 PIPE STRESS ANALYSIS PHILOSOPHY……………………………………….…..10 5.1 Analysis Software …………………………………………………..…11 5.2 Process Design Data……………………………………………...…...11 5.3 Stress Analysis Code Requirements…………………………….…11 6.0 DESIGN CONDITIONS…………………………………………………………………11 6.1 Design Life…………………………………………………...…………11 6.2 Temperatures………………………………………….………………11 6.3 Stress Range Calculations…………………………………………..11 6.4 Calculating Equipment/Pipe Support Loads ……………………11 6.5 Friction……………………………………………………………….…12 6.6 Wind………………………………………………………….………….12 6.7 Earthquak………………………………………………………………12 7.0 NOZZLE LOAD ALLOWABLES …………………………………………………...12 8.0 EQUIPMENT DESIGN CONSIDERATIONS FOR STRESS ANALYSIS……….13 8.1 Pumps……………………………………………………….…………13 8.1.1 Centrifugal Pumps …………………………..13 8.1.2 Vertical in Line Pumps…………..…………..13 8.1.3 Metering Pumps………………………………14 8.2 Centrifugal Compressors…………………………………….…….14 8.2.1 Design Conditions…………….……………..14 8.2.2 Temperature…………………………….…….14 8.2.3 Pressure………………………………………..14 8.2.4 Wind …………………………………………...14 8.2.5 Allowable loads……………………………….14 8.2.6 Friction Effect………………………………….14 8.2.7 Stress Requirements…………………….…..14 8.2.8 Piping Alignment……………………………..15 8.2.9 Recommended Modeling …………………..15

DOCUMENT TITLE: SPECIFICATION FOR PIPING FLEXIBILITY ANALYSIS

PROJECT No. :P 14364

ADCO DOC.No.: 58.99.08.1606

REV I DATE: 23-NOV-2010

CONTRACTOR DOC. No. A049-000-16-43-SP-0010 PAGE: 3 OF 30

8.3 Reciprocating Compressors……………………………………….15 8.4 Air Coolers …………………………………………………..………16 8.5 Storage Tanks………………………………………………………..17 8.6 Packaged Equipment………………………………………...……..17 8.7 Pressure Vessels & Shell and Tube Heat Exchangers………..17 9.0 GENERAL STRESS CONSIDERATIONS…………………………………………17 9.1 Glass Reinforced Epoxy Pipe………………………………..…….17 9.2 Flange Leakage……………………………………………..………...18 9.3 Pipe Sag………………………………………………………………..18 9.4 Relief Valve Discharge Loads………………………….…………..18 9.5 Slug Flow………………………………………………………………18 9.6 Hydro test……………………………………………….……………..18 9.7 Heat Tracing Elements ……………………….………………….18 9.8 Vessel Skirt Temperature…………………………………..………18 9.9 Vibration Analysis……………………………………………………19 9.9.1 Reciprocating Pumps and Compressors.18 9.9.2 Acoustic Induced Vibration………………19 9.9.3 Dynamic Analysis…………………….……19 9.9.4 Surge Analysis …………………….…….19

9.10 45°°°° Connections …………………………………………….…….19 9.11 Insulation Density……………………….………………..………..19 9.12 Sway……………………………………………………………...…..19 9.13 Equipment settlement……………………………………….……..19 9.14 Standard Pipe Supports…………………………………………...19 9.15 Special Pipe Supports ……………………………………….…..19 9.16 Spring Supports………………………………….…………………20 9.17 Temporary Pipe Supports…………………………………………20 9.18 Pipe Spans……………………………………………………………20 9.19 Indentation……………………………………………………………20 9.20 Welded Attachments………………………………………………….20 9.20.1 Trunnions & Dummy Legs…………….….20 9.20.2 Line Stops, Lugs and Pipe Shoes………20 9.20.3 Line Stop Displacements…………………20 10.0 FLEXIBILTY APPLICATIONS (PIPE STRESS ANALYSIS SPECIFIC FUNCTIONS)..20 10.1 General……………………………………………………………….20 10.2 Computer Modeling of Equipment………………………..…….20 10.2.1 Static Equipment ………………………..…20 10.2.2 Rotating Equipment……………………….20 10.2.3 Air Cooled Heat Exchangers……….……21 10.3 Modeling Friction ………………………………………………..…21

DOCUMENT TITLE: SPECIFICATION FOR PIPING FLEXIBILITY ANALYSIS

PROJECT No. :P 14364

ADCO DOC.No.: 58.99.08.1606

REV I DATE: 23-NOV-2010

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10.4 Load Case Combinations (Advisory) ………………..………..21 10.4.1 CAESAR II “Hot Sustained” Load Cases are shown below…………………………...….21 10.4.2 Slug loads …………………………...…….21 10.4.3 Seismic vs. Wind loads……………..……22 10.4.4 Load Cases………………………………..22 11.0 STRESS GROUP WORKING PRACTICES…………………………………….….23 11.1 Critical Line List…………………………………………….……….23 11.2 Filing………………………………………………………….…….….23 11.2.1 General…………………………………..……23 11.2.2 Project data………………………….………..23 11.2.3 Stress Sketches/Isometrics…………….…24 11.2.4 Calculation Format and numbering……...24 11.2.5 Nozzle Loads…………………………….…..25 11.2.6 Vessel Nozzle Load Approval………….…25 11.2.7 Vessel Clip Summary Sheets……………..25 11.2.8 Calculation Filing……………………..……..25 11.3 Checking Procedure……………………………………………….25 11.3.1 Documentation……………………………..25 11.3.2 Stress Sketch/Calc Index…………….…..25 11.3.3 Stress Sketch Geometry……………….…25 11.3.4 Calculation Input Data………………….....25 11.3.5 Calculation Output Data……………….…27 12.0 STRESS PROGRESS MONITORING………………………………………….….27 12.1 Status Reporting …………………………………………….……27 12.2 Status Descriptions and Values...............................................27 13.0 ADDITIONAL REQUIREMENTS …………………………………………………27 13.1 Supporting Arrangement…………………………………..…….27 13.2 Flange Leakage………………………………………...………….27 13.3 Stress Reporting…………………………………………….…….28 13.4 Checklists…………………………………………………………..28 13.4.1 Calculations………………………………..28 13.4.2 Isometrics …………………………..…….28 13.5 Allowable Pipe Spans ………………………………….……..28

DOCUMENT TITLE: SPECIFICATION FOR PIPING FLEXIBILITY ANALYSIS

PROJECT No. :P 14364

ADCO DOC.No.: 58.99.08.1606

REV I DATE: 23-NOV-2010

CONTRACTOR DOC. No. A049-000-16-43-SP-0010 PAGE: 5 OF 30

1.0 INTRODUCTION

1.1 PROJECT INTRODUCTION

ADCO has been chartered by their shareholders to expand sustainable crude oil

productionFrom its current level of 1.4 million barrels oil per day (MMBOPD) to 1.8

MMBOPD.Accordingly, ADCO has undertaken projects for development of its

marginal fields to help achieve this target, which involves increasing production at

existing Bab & North-East Bab oil fields and beginning productions from two new oil

fields, namely, Bida Al Qemzan & Qusahwira.

Qusahwira is a new undeveloped field located about 80 Km Southeast of existing

Asab oil field and approximately 200 km south-southeast of Abu Dhabi city. The

location of the Qusahwira field is depicted in Figure 1-1 below:

Figure 1-1

The development drilling commenced at the end of year 2006 & full field development

shall be completed in two phases. The development under Phase-1 is limited to the

southern block of the field, which involves developing Thamama Zones A/B and F. The

first phase of Qusahwira project will contribute 30 MBOPD to 1.8 MMBOPD scheme from

DOCUMENT TITLE: SPECIFICATION FOR PIPING FLEXIBILITY ANALYSIS

PROJECT No. :P 14364

ADCO DOC.No.: 58.99.08.1606

REV I DATE: 23-NOV-2010

CONTRACTOR DOC. No. A049-000-16-43-SP-0010 PAGE: 6 OF 30

year 2013 for a period of about five years. After completion of second phase, its total

production shall increase to 42.47 MBOPD. Additionally, 20 MBOPD from Mender and

South East fields shall be implemented in future.

1.2 PROJECT SCOPE

The Phase-1 of Qusahwira Full Field Development Project shall have facilities at

three locations and an interface with the existing Asab oil field. Broadly, the following

facilities are part of Phase-1 project:

- Constructing a new Central Degassing Station (CDS) at Qusahwira. It shall

include facilities as below:

o Inlet manifolds for receiving production transfer line from a new

Remote Degassing Station (RDS-1) & two direct production flow lines

o Multi phase flow meters (MPFMs)

o Two trains of three phase production separators

o Two trains of four stage gas compression

o Gas injection directly to four gas injection wells

o Two glycol contactors & one common glycol regeneration

o Vapor recovery compressor package

o Produced water treatment & disposal to five disposal wells

o Main oil Line (MOL) booster pumps and MOL pumps for exporting

crude oil to Asab CDS

o Various supporting utilities & chemical injections systems.

- Constructing a new Remote Degassing Station (RDS-1) at approximately 9.2

km southwest of the new Qusahwira CDS. The RDS -1 shall gather & test 22

production flow lines and deliver the raw crude to the Qusahwira CDS. This

shall also serve as distribution points for injection gas from the Qusahwira

CDS to 5 gas injection wells in Thamama A/B zone for pressure

maintenance besides various supporting utilities and chemical injection

facilities.

- Constructing two new Water Injection Clusters (WIC-1 and WIC2) southwest

of the Qusahwira CDS for water injection to oil wells in Thamama F zone for

DOCUMENT TITLE: SPECIFICATION FOR PIPING FLEXIBILITY ANALYSIS

PROJECT No. :P 14364

ADCO DOC.No.: 58.99.08.1606

REV I DATE: 23-NOV-2010

CONTRACTOR DOC. No. A049-000-16-43-SP-0010 PAGE: 7 OF 30

pressure maintenance including chemical injection facilities. Four wells shall

be served from WIC-1 and one well from WIC-2.

- Constructing a 20” production fluid transfer line from RDS-1 to the CDS

- Constructing a 6” gas injection trunk line from the CDS to RDS-1for

distribution to gas injection wells.

- Constructing 22 flow lines from producing wells to RDS-1 and 2 flow lines

directly to the CDS and constructing 5 gas injection flow lines from RDS-1

and 4 gas injection lines directly from the CDS.

- Constructing a 14” Main Oil Line (MOL) to the CDS at Asab oil field.

- Providing expandability for future facilities at CDS to support 62.47 MBOPD

crude oil production at Qusahwira by:

• Providing plot space for a third train of production separator, a third

train of gas compression, gas dehydration & glycol regeneration,

additional water separation tanks and additional produced water

disposal pumps.

• Providing utility systems for both phase-1 and phase-2

2.0 PURPOSE & SCOPE

This specification outlines the requirements for the stressing of piping systems for the ADCO-QUSAHWIRA Full Field Development Project. They are issued for the guidance of Stress Engineers performing stress analysis for the project.

This Procedure provides design criteria and guidelines to ensure that the piping systems for the project are in accordance with the code requirements of ASME B31.3, Process Piping and DEPs.

This Project Procedure covers:

• The minimum technical requirements for the design, stress and flexibility analysis of piping systems for the project.

• Methods and procedures to maintain consistency in the execution of work within the pipe stress group.

3.0 REFERENCES

The following documents have been used to compile this procedure.

• 31.38.01.11-Gen Piping General Requirements (SHELL DEP)

• 31.38.01.29-Gen Pipe Supports (SHELL DEP)

DOCUMENT TITLE: SPECIFICATION FOR PIPING FLEXIBILITY ANALYSIS

PROJECT No. :P 14364

ADCO DOC.No.: 58.99.08.1606

REV I DATE: 23-NOV-2010

CONTRACTOR DOC. No. A049-000-16-43-SP-0010 PAGE: 8 OF 30

• 30.99.12.0023 Plant Layout and Piping Basis of Design (ADCO STD)

• 58.99.12.1601 Piping Material Class Specification for (JOB SPEC)

• 58.99.16.2701 Pipe support standard.

• 31.22.20.31 Pressure Vessels ( Based on ASME section-VIII )

Tender bulletin related to stress analysis specification

• TB-37 PI-1

• TB-37 PI-2

• TB-39 PI-2

• TB-25 SE-4

3.1 Document Precedence

In case of conflict, the order of precedence of various specifications shall be:

• The Laws, Standards and Regulations of United Arab Emirates.

• ADNOC Codes of Practice

• Project Equipment Data Sheets.

• This Project Specification.

• Approved Technical Deviations

• ADCO Procedures, Codes & Standards

• ADCO Specifications and Engineering Practices.

• ADCO Amendments and supplements to Shell DEPs.

• Shell DEPs (v26)

• International Oil & Gas industry Codes, Standards and Recommended practices (all

where specified in the above or, where none of the above is applicable, as proposed

by Contractor and Approved by ADCO).

• Internationally recognised Oil and Gas Industry sound practices

4.0 APPLICABLE CODES AND STANDARDS

4.1 Codes, Standards and Regulations

All piping systems shall meet the requirements of this Specification, other referenced Project Specifications and the following Codes, Standards and Statutory Regulations (where applicable).The vesrsions valid on the date of contract awarded of the standards/code shall be referred.

API 610 Centrifugal Pumps for General Refinery Service

API 617 Axial & Centrifugal Compressors

API 618 Reciprocating Compressors

API 619 Rotary Type Positive Displacement Compressors

DOCUMENT TITLE: SPECIFICATION FOR PIPING FLEXIBILITY ANALYSIS

PROJECT No. :P 14364

ADCO DOC.No.: 58.99.08.1606

REV I DATE: 23-NOV-2010

CONTRACTOR DOC. No. A049-000-16-43-SP-0010 PAGE: 9 OF 30

API 650 Petroleum Storage Tanks

API 661 Air-Cooled Heat Exchangers

API 675 Positive Displacement Pumps – Rotary

ASME B31.3 Process Piping

ASME B73.1 & B73.2 Horizontal and Vertical Pumps (General Purpose)

ASME Sect. VIII Boiler and Pressure Vessel Code

ASTM Material Testing / Certification

IBC 2006 International Building Code, 2006 Edition

NACE MR 0175 Sour Service Piping

NFPA 20 Installation of Stationary Fire Pumps for Fire Protection

WRC Bulletin 107 Local Stresses in Spherical and Cylindrical Shells due to External Loadings

WRC Bulletin 297 Local Stresses in Cylindrical Shells due to External Loadings on Nozzles – Supplement to WRC Bulletin 107

WRC Bulletin 449 Guidelines for the Design and Installation of Pumps

4.2 Definitions

The following terms are defined as stated, unless otherwise indicated: COMPANY: Abu Dhabi Company for Onshore Oil Operations - ADCO.

PROJECT: Qusahwira Full Field Development Project. PROJECT MANAGEMENT CONSULTANT (PMC): Foster Wheeler International Corporation (FWIC) SHALL: Indicates a mandatory requirement. SHOULD: Indicates a strong recommendation to comply with the requirements of this document. CONTRACTOR: National Petroleum Construction Company (NPCC). The Principal shall mean ADCO in the DEP 4.3 Abbreviations

AIV Acoustic Induced Vibration

ANSI American National Standards Institute

ASCC Alkaline Stress Corrosion Cracking

ASME American Society of Mechanical Engineers

ASTM American Society for Testing And Materials

BEDD Basic Engineering Design Data

BOD Basis of Design

DEP Design Engineering Practices (Shell)

ESD Emergency Shut Down

NPS Nominal Pipe Size

DOCUMENT TITLE: SPECIFICATION FOR PIPING FLEXIBILITY ANALYSIS

PROJECT No. :P 14364

ADCO DOC.No.: 58.99.08.1606

REV I DATE: 23-NOV-2010

CONTRACTOR DOC. No. A049-000-16-43-SP-0010 PAGE: 10 OF 30

RPM Revolutions per Minute

SIF Stress Intensification Factor

SPS Special Pipe Support

TOS Top of Steel

5.0 PIPE STRESS ANALYSIS PHILOSOPHY

The Lead Piping Designer and the Lead Piping Engineer, or Lead Stress Engineer in the absence of this position, shall jointly be responsible for the production of an economic, flexible layout.

It is the responsibility of the Stress Engineer to ensure that piping is routed and supported correctly so that no damage occurs to pipe and associated equipment due to the effects of thermal growth, weight, pressure, slug flow, wind, earthquake, vibration, shock, foundation settlement or any detrimental external loads.

Every relevant mode of operation for stress critical piping systems shall be examined and every credible displacement stress range difference shall be considered.

The Minimum criteria for defining the minimum acceptable flexibility are:

a. The maximum allowable stress range of the piping material.

b. The maximum allowable forces and moments on the equipment to which the pipe is connected.

c. The maximum displacements are acceptable.

d. Excessive stresses at supporting or restraining elements

e. Unintentional disengagement of piping from its supports

f. Interference between adjacent lines due to thermal expansion or contraction of the piping system

g. Resonance due to imposed vibration or fluid induced vibration.

h. Excessive sag in piping systems, particularly those requiring slopes for drainage.

i. Special supports requiring complex design details or impractical construction tolerances.

The minimum criteria for pipe support design shall be:

a. Maximum pipe deflection between pipe supports shall be limited to 10 mm

b. Large diameter and thin wall piping shall be analyzed for crushing load at supports and reinforced as necessary

c. Pipe supports shall be allocated such as not blocking access or headroom clearance.

d. Pipes of 2” and larger laid on sleepers (if any) shall be provided with pipe shoes to avoid external corrosion at support location.

e. Excessive anchor loads, thermal loads, and friction loads for piping laid on pipe racks should be provided for in structural design.

f. Carrying/Supporting pipes from larger diameter headers is not allowed without ADCO approval.

g. Note about galvanic corrosion between piping and pipe supports of dissimilar material shall be provided in the pipe support design reports.