LEIGHTON INDIA ENGINEERING & CONSTRUCTION

BINA REFINERY PROJECT

PIPELAY ANALYSIS
STATIC CONDITION

IO185-ENG-REP-004

Document Ref. No.:

August 11,
2008

Issued for
Client
Comments

RK

GL

GP

Revision

Date

Description

Originator

Reviewed

Approved

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Leighton India Engineering & Construction

Bina Refinery Project

Pipelay analysis - Static

BINA REFINERY PROJECT

PIPELAY ANALYSIS
STATIC CONDITION
TABLE OF CONTENTS
Sections
1.0

Description

Page

INTRODUCTION

1.1 Project Description

1.2 Scope of Procedure

1.3 System Of units
1.4 Nomenclature

3
4
4

2.0

SAFETY

3.0

RESPONSIBILITIES

4.0

REFERENCES

4.1 Project Specification

4.2 Project Drawings

4.3 Codes and Standards

DESIGN DATA

5.1 Pipeline Data

5.2 Lay barge Data

5.3 Roller Position on Lay-barge and Stinger

METHODOLOGY

10

6.1 Pipelay Static analyses

10

6.2 Description of OFFPIPE

11

RESULTS

12

7.1 Static analyses

12

CONCLUSION

13

5.0

6.0

7.0
8.0

Appendices
Appendix 1.0

Leighton STEALTH Pipe-Laybarge Configuration

14

Appendix 2.0

Static Analyses OFFPIPE output

15

Appendix 3.0

Local Buckling Checks

16

August-2008

Page 2 of 16

IO185-ENG-REP-004 (Rev A)

Leighton India Engineering & Construction

Bina Refinery Project

Pipelay analysis - Static

BINA REFINERY PROJECT

PIPELAY ANALYSIS
STATIC CONDITION
1.0

INTRODUCTION

1.1

Project Description
M/s Bharat Oman Refineries Ltd. (BORL) is setting up a 6.00 MMTPA
grass root refinery at Bina in India. As part of Bina Refinery Project, M/s
Bharat Oman Refineries Limited (BORL) intend to install a Single Point
Mooring (SPM) system and approximately 17.0 km long 1219mm (48)
diameter offshore/onshore crude oil pipeline from SPM to Crude Oil
Terminal (COT) at Vadinar for unloading/ transportation of crude oil
received through ocean tankers.
Leighton scope of work includes the following:

Installation of SPM & PLEM System (at approx. 32 m water depth)
including Piling

Installation of 1219mm (48) diameter, approx. 15.0 km long
submarine pipeline with concrete coating including laying in shore
approach

Installation of 1219mm (48) diameter, approx. 2.0 km long onshore
pipeline including terminal piping works at COT

1.1

SCOPE OF REPORT
The scope of this report includes the following:

Normal pipelay analysis for static conditions during the pipe-lay
operation from Leighton barge STEALTH.

1.2

PURPOSE
The purpose of this report is to establish the following:

To find out the stresses in the pipeline during the pipe laying at
different water depths along the proposed pipeline route and
thereby establish that the pipe-laying activity is performed keeping
the pipe stresses within the permissible limits.

This analysis is done to find out the Stinger tip, Bottom tension at
touch down, Suspended span length, Maximum overbend stress,
and Maximum sagbend stress.

August-2008

Page 3 of 16

IO185-ENG-REP-004 (Rev A)

Leighton India Engineering & Construction

Bina Refinery Project

Pipelay analysis - Static

BINA REFINERY PROJECT

PIPELAY ANALYSIS
STATIC CONDITION

1.3

SYSTEM OF UNITS
The International system (SI) of units is adopted as the main system of the
pipelay analysis.

1.4

NOMENCULTURE
BOP
DLB
DnV
KP
LFP
mm
MPa
MT

August-2008

Bottom Of Pipe
Derrick Lay Barge
Det norske Veritas
Kilometer Point
Land Fall Point
millimeter
Megapascal
Metric Tonne

Page 4 of 16

IO185-ENG-REP-004 (Rev A)

Leighton India Engineering & Construction

Bina Refinery Project

Pipelay analysis - Static

BINA REFINERY PROJECT

PIPELAY ANALYSIS
STATIC CONDITION
2.0

SAFETY
All activities that are scheduled to be carried out in accordance with this
document, the contract requirements, approved Leighton Safety
Procedures and any specific job safety analysis conducted to
commencement of work.

August-2008

Page 5 of 16

IO185-ENG-REP-004 (Rev A)

Leighton India Engineering & Construction

Bina Refinery Project

Pipelay analysis - Static

BINA REFINERY PROJECT

PIPELAY ANALYSIS
STATIC CONDITION
3.0

RESPONSIBILITIES

1.

Project Manager shall be responsible for approval of this report.

2.

The Construction Manager shall be responsible for implementation of the

specific aspects of this report.

3.

Actions may be delegated, but responsibility shall not be delegated.

Definitions:
Use of the Word shall within this document indicates a mandatory
requirement.
Use of the word should within this document indicates a preferred
requirement.

August-2008

Page 6 of 16

IO185-ENG-REP-004 (Rev A)

Leighton India Engineering & Construction

Bina Refinery Project

Pipelay analysis - Static

BINA REFINERY PROJECT

PIPELAY ANALYSIS
STATIC CONDITION
4.0

REFERENCES
The latest revision of the following reference documents shall be used in
conjunction with this report.

4.1

Project Specifications

Number
1203-001-16-56-SD-03

Title
Geotechnical Investigation Report for
SPM System
Design Premise for Residual
Engineering

IO185-ENG-REP-001

4.2

Project Drawings

Number
1203-002-16-71-1001 to 1005

Title
Pipeline Alignment Sheet From PLEM to LFP

1203-002-16-71-1006 to 1008

Pipeline Alignment Sheet From LFP to COT

IO185-ENG-DWG-505

Finalized Pipeline Route Drawing

4.3

Codes and standards

Codes

Title
Rules for Submarine Pipeline Systems.

DNV - 1981

August-2008

Page 7 of 16

IO185-ENG-REP-004 (Rev A)

Leighton India Engineering & Construction

Bina Refinery Project

Pipelay analysis - Static

BINA REFINERY PROJECT

PIPELAY ANALYSIS
STATIC CONDITION

5.0

DESIGN DATA
The analyses described in this document are based on the pipeline data,
material properties and barge input data as provided in the following
sections. The pipelay analyses are performed using nominal pipe
properties.

5.1

Pipeline Data
The pipeline data are as per Pipeline Alignment Sheet from PLEM to LFP.
(Drawing No. 1203-002-16-71-1004 & 1005) are presented in Table 5.1
Table 5.1: Pipeline Data
Sections
Outside Diameter
Material Grade
Wall Thickness
Steel Density
Corrosion Coating
Corrosion Coating Thickness
Concrete Coating Thickness
Field Joint Coating
Field Joint Coating Density

KP 0.0 to KP 2.3
KP 2.3 to KP 9.5
& KP12.3 to LFP
1219.2mm(48-in)
API 5L GRADE (X-65)
20.6mm
7850 kg/m3
Coal Tar Enamel
4.8mm
100mm
130mm
As per EIL Spec. No.6-71-0045 Rev.2
1025 kg/m3

.
5.2

Lay barge Data

Lay barge data used in the analysis is presented in Table 5.2 and the
barge configuration drawing is presented in Appendix 1.
Table 5.2: Lay barge data
Description
Length
Breadth
Moulded depth
Operating draft
Barge trim
Hitch co-ordinates(wrt barge deck)
Number of tensioner
Tensioner capacity

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Page 8 of 16

Data
100.585M
30.480M
6.16M
3.6m
Varies for water depth
Y = -2.5m, x = -0.75m
2
50 tonnes each

IO185-ENG-REP-004 (Rev A)

Leighton India Engineering & Construction

Bina Refinery Project

Pipelay analysis - Static

BINA REFINERY PROJECT

PIPELAY ANALYSIS
STATIC CONDITION
Number of supports on Barge
Crane Capacity
Track Roller Capacity
Stinger Roller Capacity
5.3

8 (including 2 tensioner)
250 Tonnes
100 Tonnes
60 Tonnes

Roller Position on Laybarge and Stinger

The lay barge and stinger roller positions used in the design are presented
in Table 5.3 and Table 5.4:
Table 5.3: Roller Position on Laybarge
Sl-No.
X Coordinate
Roller No. 1
89.471
Roller No. 2
78.873
Roller No. 3
66.681
Roller No. 4
54.490
Tensioner No. 1
42.425
Tensioner No. 2
30.289
Roller No. 5
20.072
Roller No. 6
6.02

Y Coordinate
5.436
4.93
4.349
3.767
3.191
2.542
1.87
0.62

Note: Roller positions on lay barge are based on (0, 0) barge stern coordinate

Table5.4: Stinger Roller Position

Support
X Coordinate
Roller No. 2
-8.873
Roller No. 4
-20.072
Roller No. 6
-29.721

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Page 9 of 16

Y Coordinate
-1.198
-2.867
-4.557

IO185-ENG-REP-004 (Rev A)

Leighton India Engineering & Construction

Bina Refinery Project

Pipelay analysis - Static

BINA REFINERY PROJECT

PIPELAY ANALYSIS
STATIC CONDITION

METHODOLOGY

6.1

Pipelay Static Analyses

The installation of the pipeline will be carried out in accordance with the
DnV-1981 and the design premise document (Ref-2). The normal pipelay
during static conditions will be performed for various water depths using
OFFPIPE program. In the pipe-lay analysis following external forces will
be considered.

Uniformly distributed weight of pipe

Applied tensions at the lay barge tensioners
External hydrostatic pressure
Reaction loads from the supporting rollers

The pipeline stresses are calculated using the equivalent stress

formulations in DnV-1981 which is as below.
e = (x2 + y2 - x . y)
Where,
e = Equivalent Stress in MPa
x = Longitudinal Stress in MPa
y = Hoop Stress in MPa
6.2

Description of OFFPIPE
The Static analysis is performed using OFFPIPE program. OFFPIPE is
sophisticated finite element method based on commercial computer
program. It has been developed specifically for modeling and structural
analysis of non linear problems encountered in the installation and
operation of offshore pipelines.
OFFPIPE is based on the non linear matrix, finite element method
developed specifically for analysis of flexible offshore beam and cable
structures. This method is generalization of the classical, linear EulerBernoulli theory traditionally used for the analysis of offshore platform and
similar structures. This method is equivalent to the numerical (Galerkin)
solution of the exact non linear differential equation of motion for a
continues beam, which is subjected to large deflections and non-linear
material behavior.

August-2008

Page 10 of 16

IO185-ENG-REP-004 (Rev A)

Leighton India Engineering & Construction

Bina Refinery Project

Pipelay analysis - Static

BINA REFINERY PROJECT

PIPELAY ANALYSIS
STATIC CONDITION
The coordinates of the pipe supports and tensioners on the lay-barge are
based on the typical configuration provided by Leighton (Refer Appendix1). These coordinates are provided in Table 5.3. The standard operational
draft for the analysis is 3.6m and the position of the vessel is defined in
the input data by specifying the draft, heading and trim angle of the vessel.
The stinger is modeled as a rigid truss which has fixed curvature with a
hinged end. The undeformed geometry of the stinger is defined by the
stinger roller coordinates which are provided in Table 5.4.
The pipeline properties are modeled as per the pipeline data provided in
Table 5.1. However, concrete coating stiffness is ignored for stress
computation as it is conservative.
Local buckling checks are performed in accordance with the DnV-1981.

August-2008

Page 11 of 16

IO185-ENG-REP-004 (Rev A)

Leighton India Engineering & Construction

Bina Refinery Project

Pipelay analysis - Static

BINA REFINERY PROJECT

PIPELAY ANALYSIS
STATIC CONDITION
7

RESULTS

7.1

Static Analysis.
The static analyses were carried out for water depths of 5m, 8m, 10m,
20m, 25m and 30m. Table 7.1 summarises the tensions required during
pipe-lay in order to maintain the pipeline integrity during pipe-laying. The
water depths considered are inclusive of tidal height. The detail computer
outputs are provided in Appendix 2.
The static analyses indicate that the stresses in the pipe at the overbend
and sagbend were within the allowable stresses. The highest overbend
stresses recorded in the pipe is 66.92% of SMYS and highest sagbend
stress is 61.21% of SMYS.
Local buckling checks were carried out to ensure that pipeline is not
locally buckled. The local buckling checks are provided in Appendix-3 and
utilization ratio is less than 1 for all cases.
Table 7.1: Lay Stress Analysis Results

File
Name

Water
Depth
(m)

S05m
S08m
S10m
S20m
S25m
S30m

5
8
10
20
25
30

Barge
Stinger
Tension
Tip at
(Tonnes) Depth
(m)

August-2008

40
50
30
60
40
40

-0.96
-1.42
-1.91
-2.06
-2.06
-2.06

Bottom
Tension
@ Touch
Down
(Tonnes)
24.17
33.51
7.27
32.34
19.87
18.76

Trim
Angle
(deg.)

Suspended
Span Length
(m)

Max.
Overbend
Stress
(% SMYS)

Max. Sag
Bend Stress
(% SMYS)

0
0
0
0
0
0

78.68
100.47
87.66
128.10
169.04
182.87

238.88(53.32)
299.80(66.92)
256.54(57.26)
279.37(62.36)
263.29(58.77)
292.18(65.22)

147.38(32.90)
151.57(33.83)
230.86(51.53)
274.21(61.21)
205.43(45.86)
224.04(50.01)

Page 12 of 16

IO185-ENG-REP-004 (Rev A)

Leighton India Engineering & Construction

Bina Refinery Project

Pipelay analysis - Static

BINA REFINERY PROJECT

PIPELAY ANALYSIS
STATIC CONDITION

Conclusion
The pipe-lay analyses for the 48-inch pipeline have been performed for the
proposed pipe-lay barge STEALTH configuration. The normal static pipelay analyses performed indicate that the pipeline stresses are within the
allowable limits in accordance with the DnV-1981.

August-2008

Page 13 of 16

IO185-ENG-REP-004 (Rev A)

Leighton India Engineering & Construction

Bina Refinery Project

Pipelay analysis - Static

BINA REFINERY PROJECT

PIPELAY ANALYSIS
STATIC CONDITION

Appendix 1.0
Leighton Lay-Barge STEALTH Details

August-2008

Page 14 of 16

IO185-ENG-REP-004 (Rev A)

Leighton India Engineering & Construction

Bina Refinery Project

Pipelay analysis - Static

BINA REFINERY PROJECT

PIPELAY ANALYSIS
STATIC CONDITION

Appendix 2.0
Static Analyses OFFPIPE output

August-2008

Page 15 of 16

IO185-ENG-REP-004 (Rev A)

Leighton India Engineering & Construction

Bina Refinery Project

Pipelay analysis - Static

BINA REFINERY PROJECT

PIPELAY ANALYSIS
STATIC CONDITION

Appendix 3.0
Local Buckling Checks

August-2008

Page 16 of 16

IO185-ENG-REP-004 (Rev A)