pd 8010-2 presentation april 2005 new
TRANSCRIPT
PD 8010 Slide 1 of 40
PD 8010 : 2004Code of practice for pipelines
by Bob Inglis (JP Kenny – Leader of PSE/17/2 WG2 Pipelines Offshore)
Offshore Pipelines and how PD 8010 differs from the superseded BS 8010 and how it works in association with BS EN 14161 : 2003
PD 8010 Slide 2 of 40
PSE/17/2 WG2 Pipelines Offshore Committee
• Bob Inglis, JP Kenny
• John Lawson, Chevron Texaco
• Mike Little, Binnie Black & Veatch
• Tony Barber, Kellogg Brown & Root
• Martin East, Trevor Jee Associates
• Graham Stewart, Lloyd’s Register
PD 8010-2 Subsea Pipelines
PD 8010 Slide 3 of 40
PD 8010-2 Subsea Pipelines
How does PD 8010-2 work in association with BS EN-14161?
It has provided a more comprehensive guideline for design, construction and operation of offshore pipelines utilising familiar and recognised methodologies
How does PD 8010-2 differ from BS 8010 Part 3?
General design methodology is unchanged
PD 8010 Slide 4 of 40
1. SCOPE2. NORMATIVE REFERENCES3. TERMS & DEFINITIONS4. GENERAL5. PIPELINE SYSTEM DESIGN6. PIPELINE DESIGN7. DESIGN OF STATIONS & TERMINALS8. MATERIALS & COATINGS9. CORROSION MANAGEMENT10. CONSTRUCTION MANAGEMENT11. TESTING12. PRE-COMMISSIONING &
COMMISSIONING13. OPERATION,MAINTENANCE &
ABANDONMENT
PD 8010-2 Structure (cont.)
•Layout of PD 8010 is consistent with that of EN 14161
1. SCOPE2. NORMATIVE REFERENCES3. TERMS & DEFINITIONS4. HEALTH, SAFETY & ASSURANCE5. DESIGN - SYSTEM & SAFETY6. DESIGN – MECHANICAL INTEGRITY7. DESIGN – LANDFALLS, RISERS & TIE-INS8. DESIGN – MATERIALS & COATINGS9. DESIGN – CORROSION MANAGEMENT10. CONSTRUCTION – FABRICATION &
INSTALLATION11. CONSTRUCTION – TESTING12. PRE-COMMISSIONING &
COMMISSIONING13. OPERATIONS, MAINTENANCE &
INTEGRITY MANAGEMENT14. ABANDONMENT
PD 8010 Slide 5 of 40
PD 8010-2 Structure
1. SCOPE
2. NORMATIVE REFERENCES
3. TERMS & DEFINITIONS
4. HEALTH, SAFETY & ASSURANCE
5. DESIGN - SYSTEM & SAFETY
6. DESIGN – MECHANICAL INTEGRITY
7. DESIGN – LANDFALLS, RISERS & TIE-INS
8. DESIGN – MATERIALS & COATINGS
9. DESIGN – CORROSION MANAGEMENT
10. CONSTRUCTION – FABRICATION & INSTALLATION
11. CONSTRUCTION – TESTING
12. PRE-COMMISSIONING & COMMISSIONING
13. OPERATIONS, MAINTENANCE & INTEGRITY MANAGEMENT
14. ABANDONMENT
STATIONS & TERMINALS
Consistent with Part 1
PD 8010 Slide 6 of 40
ANNEXES
A (normative) QUALITY ASSURANCE
B (normative) RECORDS & DOCUMENT CONTROL
C (informative) HAZARDS IN PIPELINE DESIGN
D (normative) SAFETY EVALUATION OF PIPELINES
E (normative) PIPELINE ROUTE SELECTION
F (normative) LOADS
G (informative) BUCKLING
H (normative) ENVIRONMENTAL CONDITIONS
PD 8010-2 Structure (cont.)
PLANNING & LEGAL
A - EXTENT OF PIPELINE SYSTEMS FOR CONVEYING OIL & GAS THAT ARE COVERED BY THIS PART OF PD 8010
B /
C /
D /
E /
F /
G /
H /
I /
PD 8010 Slide 7 of 40
Section 1-3 :Scope, References and Definitions
Section 1 defines the extent of pipeline systems covered by PD 8010 Part 2, which is little different from BS 8010 Part 3. Note the code does not cover sea outfalls or fluid umbilicals
Sections 2 and 3 cover references and definitions
PD 8010 Slide 8 of 40
Section 4 : Health, Safety & Assurance
Section 4 gives recommendations for goal setting in terms of
•Health, Safety & Environment
•Competence Assurance
•Quality Assurance
•Design, Construction and Commissioning Assurance
•Operation and Abandonment Assurance
It defines need for competent personnel (C.Eng or equivalent), need for QA/QC systems, document/records control, a design procedure and a design change procedure during operation.
PD 8010 Slide 9 of 40
Section 4 : Design Flowchart (example)
Design Criteria
Basic Design
Mech. Design Checks
Corrosion Design
Design of Components
Design for Operation
PD 8010 Slide 10 of 40
Section 5 : System & Safety
Section 5 defines
•system limits, (unchanged from BS 8010),
•fluid categorisation,
•process design requirements,
•pressure control (overpressure limited to 110% MAOP),
•need for a safety evaluation
PD 8010 Slide 11 of 40
Section 5 : Fluid Categorisation
Consistent with Part 1 (obviously!) and effectively so with EN 14161
PD 8010 Slide 12 of 40
Section 6 : Design - Mechanical Integrity
Section 6 provides guidance on:
•Pressure definition and pressure design of pipe and components
•Stress based design criteria;
•Strain based design criteria;
•Buckling and collapse;
•Fracture and Fatigue;
•Bundles and Pipe-in-pipe;
•Stability (hydrodynamic and geotechnic)
•Spanning & crossings
PD 8010 Slide 13 of 40
Section 6 : Design and Test Pressure Definition
1. Pressure
2. Test Pressure
3. 1.1 x Internal Design Pressure
4. Net Internal Design Pressure
5. Maximum Allowable Operating Pressure
6. Static Head Pressure
7. Hydraulic Gradient
8. Ground Profile
9. Surge Pressure
10. Pressure to overcome friction losses
11. Recommended back pressure
12. Distance along pipeline
PD 8010 Slide 14 of 40
Design Stress Criteria are effectively unchanged from BS 8010 Part 3, as follows:
Section 6 : Stress Based Design Criteria
PD 8010 Slide 15 of 40
•BS EN 14161 allows a design factor up to 0.83 to be used. The design factors recommended for UK use are given. Higher design factors may be used for all or part of a pipeline system, provided that an equivalent level of safety is achieved throughout the system under consideration and across all relevant limit states. A full risk assessment is recommended if higher design factors are used and might be subject to regulatory review
•Lower design factors are now extended to include landfalls
•While BS 8010 stated consideration should be given to reduction in SMYS for temperatures in excess of 1200C, PD 8010 states that account should be taken of the variation of strength with temperature on the basis of verifiable test data appropriate to the material under consideration.
•Seabed design factors now specifically include tie-ins
Section 6 : Stress Based Design Criteria (cont.)
PD 8010 Slide 16 of 40
Section 6 : Strain Based Design Criteria
Design Strain Criteria are consistent with BS 8010 Part 3. For application of strain based approach the following are required:
•Hoop Stress criterion must be met
•Plastic component of equivalent strain <0.1%, (ref. state for zero strain is as-built state - post pressure test)
•Plastic strain only occurs on first operation, not during subsequent cycles
• Do/tnom<60
•Welds possess adequate fracture resistance, demonstrated by direct testing or fracture toughness testing and analysis in accordance with B 7448 and 7910
•Weld alignment is controlled
•Fatigue and fracture analysis is performed
•Buckling limit states are checked
PD 8010 Slide 17 of 40
Section 6 : Buckling and Collapse
Buckling and Collapse Criteria are unchanged from BS 8010, (although errors in original formulae corrected!)
PD 8010 Slide 18 of 40
Section 6 : Fracture and Fatigue
Fracture – Prime means of fracture resistance is by specification of sufficient toughness to ensure running fracture arrest.
Fatigue – A consistent approach with Part 1 has been adopted. Guidance is given for developing methodology with reference to BS 7608 and BS 7910.
PD 8010 Slide 19 of 40
Section 6 : Pipe-in-pipe, Bundles
Descriptive guidance is given on aspects to be considered in design
(Note – aspects of flexible pipe design, previously included in BS 8010 Part 3, have now been deleted, reference is made to API RP 17B and ISO 13628, (API 17J for flexible risers))
PD 8010 Slide 20 of 40
Section 6 : Stability, Spanning & Crossings
•The basic 2D stability check from BS 8010 Part 3 is retained, with reference made to DNV and AGA for alternative approaches.
•Need for spans assessment is recognised, no prescriptive methodology laid down
•Crossings – specification of minimum crossing angle of 300 from BS 8010 Part 3 has been omitted
PD 8010 Slide 21 of 40
Section 7 : Design - Landfalls, risers and tie-ins
•Most of the narrative from BS 8010 has been retained,
•Additional reference is made to branch connections (tees, Y’s) connectors and to valve selection including actuators
•Considerations for pigging are included
•Pipeline protection methods are outlined
•Reference to the Safety Case Regulations (1996) is included for emergency shut down systems
PD 8010 Slide 22 of 40
Section 8 : Design - Materials and Coatings
•Reference standards for linepipe have been updated including high alloy steels (duplex, superduplex)
•Requirements for fracture toughness, crack arrest highlighted
•Need to avoid detrimental intermetallic phases (I.e sigma phase) in ferritic/austenitic steels is highlighted.
•Recommendations for pipeline components (flanges, bends, valves and fittings) included.
•Coatings, including concrete and insulation materials, addressed
PD 8010 Slide 23 of 40
Section 9 : Design – Corrosion Management
Section 9 gives guidelines for establishing a corrosion management programme including the need for in service assessments and maintenance of corrosion mitigation equipment.
•Both internal and external corrosion issues are described.
•Reference standards for internal coatings have been updated.
•Reference is given to DNV-RP-F103 for cathodic protection design, but with a note that ISO/DIS 155892-01 is in preparation
PD 8010 Slide 24 of 40
Section 10 : Construction – Fabrication & Installation
•The need for establishing safety and construction plans is highlighted and the appointment of ‘competent persons’ to run construction operations. Reference is made to consideration of EIA’s (Environmental Impact Assessment) in advance of construction work.
•BS 4515-1 and 4515-2 are retained as reference standards for welding
•Guidance on installation by S-lay, towing, reeling and J-lay is provided – the emphasis is on control, planning and management of activities rather than prescriptive criteria
PD 8010 Slide 25 of 40
Section 11 : Construction – Testing
•The basic requirement for a 24-hour pressure test to 90% SMYS or 1.5 x Design Pressure is unchanged from BS-8010 Part 3, i.e., different from the BS EN 14161 proposed 8-hour hold period. (Note this section is identical in the two parts of PD 8010, hence some of the criteria stated are not relevant to practicalities of offshore lines.)
•Valves should not be used as end closures unless fully rated to the hydro-test pressure
•No specific duration is stated for the hold period prior to commencement of the 24 hour hold period, this will require judgement to allow for residual air to go into solution, temperature stabilisation and time dependent pipe straining
PD 8010 Slide 26 of 40
Section 11 : Construction – Testing (cont.)
•It is recognised that 0.2% allowable air content may be impractical in short sections
•The 24-hour hold duration may be reduced for sections of less than 20m3 volume
•Leak testing to 110% MAOP is called for, but use of non-tested ‘golden’ welds is accepted subject to specific criteria. The number of these should be minimised.
•The duration of leak testing is not specified, (previously advised as 3 hours typically). It should be sufficient to ensure that all potential leak paths can be verified.
PD 8010 Slide 27 of 40
Section 12 : Pre-commissioning and Commissioning
•Environmental considerations for disposal of hydro test water are addressed
•Options for drying pipelines, as necessary are included, namely• Air drying•Glycol/methanol swabbing•Vacuum drying
•Requirements for product introduction and start-up are highlighted, in particular the need to ensure operating procedures and safety systems are in place and that formal handover of operational responsibility is made
PD 8010 Slide 28 of 40
Section 13 : Operation, Maint. and Integrity Assurance Man.
This section has been introduced as little guidance was previously given in BS 8010 Part 3. This was more aimed at design and construction.
It draws on and expands on the guidance given in BS EN 14161.
It states the need for the following plans and gives recommendations for items that should be included, namely:
•Integrity Management System
•Operating and Maintenance Plan
•Incident and Emergency Response Plan
PD 8010 Slide 29 of 40
Section 13 : Operation, Maint. and Integrity Assurance Man.
Emphasis is placed on implementation of the following:•Permit-to-work Systems•Training•Authority and 3rd party liaison programmes•Active maintenance of records
The importance is noted of a control plan for any in-service changes in operating conditions. A full update of appropriate design documentation is recommended.
Above all, the criticality of an ‘active’ Integrity Assurance Programme is highlighted, especially with regard to changes in the design condition.
PD 8010 Slide 30 of 40
Section 14 : Abandonment
Reference is made to the Pipelines Act (1962) and Pipeline Safety Regulations (1996) “in respect of general duties to preserve safety throughout the lifetime of the pipeline (including abandonment)”
The onus remains with the Operator to ensure an an abandoned line remains safe and that accurate records are maintained.
PD 8010 Slide 31 of 40
Appendix A : Quality Assurance
Appendix A gives recommendations on content of Quality plans for Design, Material Procurement and Construction Phases
PD 8010 Slide 32 of 40
Appendix B : Records and Document Control
Appendix B outlines typical deliverables documentation for the following areas of a pipeline system:
•Design
•Procurement
•Construction
•Pressure Testing And Pre-commissioning
•Survey
•Inspection and Maintenance
PD 8010 Slide 33 of 40
Appendix C : Hazards in Pipeline Design
Appendix C provides information on potential Hazards of which Pipeline System Design should take account, both in terms of internal fluid (gas or liquid phase).
It lists a number of external hazards for consideration but is not meant to be an exhaustive list!.
PD 8010 Slide 34 of 40
Appendix D : Safety Evaluation of Pipelines
Appendix D provides guidance on risk assessment of pipeline systems
It recommends systematic hazard identification, consequence analysis.
Acceptance criteria need to be established and mitigation measures implemented for unacceptable levels of risk.
Systematic risk assessments are required which should be maintained and updated through the pipeline lifetime.
3
2
1
1
A
Frequent
33333Negligible4
33332Marginal3
33321Critical2
33211Catastrophic1
F
Impossible
E
Extremely Improbable
D
Remote
C
Occasionally
B
Reasonably Possible
Descriptive
Word
Hazard Severity Category
PROBABILITY RATING
3
2
1
1
A
Frequent
33333Negligible4
33332Marginal3
33321Critical2
33211Catastrophic1
F
Impossible
E
Extremely Improbable
D
Remote
C
Occasionally
B
Reasonably Possible
Descriptive
Word
Hazard Severity Category
PROBABILITY RATING
WBS -06: PIPELAY
PRE-MITIGATION POST-MITIGATION
RESIDUAL RISK
SP8 Construction SP1-8 Infrastructure SP8 Construction SP1-8 Infrastructure
ID/W
BS
EVENT CAUSE CONSEQUENCE/
Pro
b.
Sev.
RP
C
Pro
b.
Sev.
RP
C
MITIGATION
Pro
b.
Sev.
RP
C
Pro
b.
Sev.
RP
C
15 Loss of Stinger Critical Fabrication defect
Fatigue
Severe weather
Collision
Major vessel damage
Loss of Pipe
Damage to 3rd party lines
D 1 2 D 1 2 Regular diver inspections
Marine control procedures
E 1 3 E 1 3
16 Vessel Collision Pipe Cargo Barge
AHT
Survey Vessel
Supply Boats
3rd party vessel
Major vessel damage
Personal Injury
Loss of Pipe
C 2 2 - - - Exclusion zones
Marine Control procedures
Emergency Response procedures/ Bridging Docs.
E 2 3 - - -
17 Helicopter crash
Bad weather
Poor communications
Mechanical failure
Major vessel damage
Personal injury
Loss of Helicopter
E 1 3 E 1 3 Training
Emergency Response procedures/ Bridging Docs.
E 1 3 E 1 3
18 Pipe impact on stinger rollers
Bad weather
Damage to concrete coating
A 3 3 - - - Stinger monitoring
Impose weather criteria
B 3 3 - - -
PD 8010 Slide 35 of 40
Appendix D : Safety Evaluation of Pipelines (cont.)
HSE levels of individual risk are defined as follows:
Criterion Risk (frequency of occurrence per annum)
Broadly acceptable <10-6
Tolerable 10-6 - 10-4
Unacceptable <10-4
For risks identified in the tolerable range, mitigation measures should be implemented to reduce the risk ‘as low as reasonably practical’ (ALARP)
PD 8010 Slide 36 of 40
Appendices E - F
Appendix E gives guidance on factors to be considered in routing pipelines and and also for collection of survey data, both geophysical and environmental.
Appendix F (effectively reproduced from BS 8010 Part 3) defines different types of load
Appendix G reproduces the buckling checks from BS 8010, but with a couple of arithmetical corrections noted which had lain dormant since publication!
The need to address upheaval buckling is also included, but only in a qualitative manner, recognising the complexity of the analysis.
Appendix H retains the basic approach to derivation of appropriate wave/current conditions and for determining environmental loads, I.e. based on well used methodologies.
The use of alternative approaches, (such as DNV), is also recognised.
PD 8010 Slide 37 of 40
PD 8010-2 : One Year On….
To date, from PSE/17/2 committee viewpoint, there has been little feedback from the industry!
This either implies acceptance and approval of the code requirements, or apathy!
PD 8010 Slide 38 of 40
PD 8010-2 : One Year On….
Issues raised to date :
•Strain based design criteria (unchanged from BS8010 Part 3) are dated and perhaps don’t reflect current state of the art.
•Guidance and applicability to HP/HT pipelines is limited, since a strict ASD approach is limited.
•Applicability for deep water applications is limited
•Hydrotesting criteria are constraining, (especially in regard to HP/HT applications)
•There is a never ending battle in keeping cross
references up to date!
PD 8010 Slide 39 of 40
PD 8010-2 : Future Plans
There are no immediate plans for issue of updates, but the committee remains committed to responding to industry feedback
This involves dealing with specific issues raised and, if necessary, issue of amendments and clarifications (none identified to date)
Long term, the committee may review the structure of the code and expand specific topics, including pipeline operational issues, adoption of limit state design techniques and continued harmonisation with other international standards
PD 8010 Slide 40 of 40
Close
BS 8010 Part 3 was never significantly broke, so didn’t require significantly fixing!
The introduction of BS EN 14161 has nevertheless necessitated a revision of the widely accepted and respected British Standard.
This permits engineers to continue to design, construct and operate pipelines in a safe manner.
The industry has accepted the implementation of PD 8010-2 as it has allowed ‘business as usual’ to continue!
Nevertheless the committee recognises the need to reflect industry needs and will continue to review and update the code as required.