Pd 8010-2 Presentation April 2005 New

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Offshore Pipelines and how PD 8010 differs from the superseded BS 8010 and how it works in association with BS EN 14161 : 2003


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 8010-2 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


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 8010-2 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


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 /


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


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.


Section 4 : Design Flowchart (example)

Design Criteria

Basic Design

Mech. Design Checks

Corrosion Design

Design of Components

Design for Operation


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


Section 5 : Fluid Categorisation

Consistent with Part 1 (obviously!) and effectively so with EN 14161


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


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


Design Stress Criteria are effectively unchanged from BS 8010 Part 3, as follows:

Section 6 : Stress Based Design Criteria


•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.)


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


Section 6 : Buckling and Collapse

Buckling and Collapse Criteria are unchanged from BS 8010, (although errors in original formulae corrected!)


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.


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))


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


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


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


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


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


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


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.


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


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


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.


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.


Appendix A : Quality Assurance

Appendix A gives recommendations on content of Quality plans for Design, Material Procurement and Construction Phases


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


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!.


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 - - -


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)


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 8010-2 : 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 8010-2 : 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 8010-2 : 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


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.

Documents

Pd 8010-2 Presentation April 2005 New