6.57 Onshore Pipeline Mechanical Design Report

31
KCP-GNS-PLD-DRP-0004 Rev: 03 Project Title: Kingsnorth Carbon Capture & Storage Project Page 1 of 31 Document Title: Onshore Pipeline Mechanical Design Report Kingsnorth CCS Demonstration Project The information contained in this document (the Information) is provided in good faith. E.ON UK plc, its subcontractors, subsidiaries, affiliates, employees, advisers, and the Department of Energy and Climate Change (DECC) make no representation or warranty as to the accuracy, reliability or completeness of the Information and neither E.ON UK plc nor any of its subcontractors, subsidiaries, affiliates, employees, advisers or DECC shall have any liability whatsoever for any direct or indirect loss howsoever arising from the use of the Information by any party. Onshore Pipeline Mechanical Design Report Table of Contents 1 Summary ......................................................................................................................... 3 2 Introduction ...................................................................................................................... 5 2.1 Scope of Document .................................................................................................. 5 2.2 Definitions ................................................................................................................. 6 2.3 Abbreviations ............................................................................................................ 6 2.4 System of Units......................................................................................................... 6 2.5 Cross References ..................................................................................................... 6 3 Design Data ..................................................................................................................... 7 3.1 Linepipe Properties ................................................................................................... 7 3.2 Operating Data ......................................................................................................... 8 3.3 Environmental Data .................................................................................................. 8 3.4 External Corrosion Protection ................................................................................... 8 4 Mechanical Calculations .................................................................................................. 9 4.1 Wall Thickness Calculations ..................................................................................... 9 4.2 Circumferential Stresses ......................................................................................... 10 4.3 Longitudinal Stresses for Fully Restrained Pipeline................................................. 10 4.4 Equivalent Stress for Fully Restrained Pipeline ....................................................... 11 4.5 Anchor Force and Displacement, Partly Restrained Pipeline .................................. 12 4.6 Anti-buoyancy Assessment ..................................................................................... 13 4.7 Upheaval Buckling .................................................................................................. 13 4.8 API RP 1102 Road Crossing Assessment .............................................................. 14 5 Mandatory References .................................................................................................. 15 5.1 Codes and Standards ............................................................................................. 15 6 Supporting References .................................................................................................. 16 6.1 Project Documentation............................................................................................ 16 6.2 External Documentation .......................................................................................... 16 7 Appendix A, PD 8010-1 Mechanical Design Calculations .............................................. 17 7.1 Wall Thickness........................................................................................................ 17 7.2 Expansion ............................................................................................................... 18 7.3 Upheaval Buckling .................................................................................................. 24 7.4 Specific Gravity (Bouyancy) .................................................................................... 25 8 Appendix B, API RP 1102 Uncased Road Crossing Assessment .................................. 26 9 Appendix C, DNV RP-J202 Wall Thickness Calculations ............................................... 30 9.1 Extract from Pressure Containment Calculations .................................................... 31

Transcript of 6.57 Onshore Pipeline Mechanical Design Report

Page 1: 6.57 Onshore Pipeline Mechanical Design Report

KCP-GNS-PLD-DRP-0004 Rev: 03

Project Title: Kingsnorth Carbon Capture & Storage Project Page 1 of 31

Document Title: Onshore Pipeline Mechanical Design Report

Kingsnorth CCS Demonstration Project The information contained in this document (the Information) is provided in good fai th. E.ON UK plc, i ts subcontractors, subsidiaries, affi l iates, employees, advisers, and the Department of Energy and Cl imate Chan ge (DECC) make no representation or warranty as to the accuracy, rel iabi l i ty or completeness of the Information and neither E.ON UK plc nor any of i ts subcontractors, subsidiaries, affi l iates, employees, advisers or DECC shal l have any l iabil i ty whatsoever fo r any direct or indirect loss howsoever arising from the use of the Information by any party.

Onshore Pipeline Mechanical Design Report Table of Contents 1 Summary ......................................................................................................................... 3 2 Introduction ...................................................................................................................... 5

2.1 Scope of Document .................................................................................................. 5 2.2 Definitions ................................................................................................................. 6 2.3 Abbreviations ............................................................................................................ 6 2.4 System of Units ......................................................................................................... 6 2.5 Cross References ..................................................................................................... 6

3 Design Data ..................................................................................................................... 7 3.1 Linepipe Properties ................................................................................................... 7 3.2 Operating Data ......................................................................................................... 8 3.3 Environmental Data .................................................................................................. 8 3.4 External Corrosion Protection ................................................................................... 8

4 Mechanical Calculations .................................................................................................. 9 4.1 Wall Thickness Calculations ..................................................................................... 9 4.2 Circumferential Stresses ......................................................................................... 10 4.3 Longitudinal Stresses for Fully Restrained Pipeline ................................................. 10 4.4 Equivalent Stress for Fully Restrained Pipeline ....................................................... 11 4.5 Anchor Force and Displacement, Partly Restrained Pipeline .................................. 12 4.6 Anti-buoyancy Assessment ..................................................................................... 13 4.7 Upheaval Buckling .................................................................................................. 13 4.8 API RP 1102 Road Crossing Assessment .............................................................. 14

5 Mandatory References .................................................................................................. 15 5.1 Codes and Standards ............................................................................................. 15

6 Supporting References .................................................................................................. 16 6.1 Project Documentation ............................................................................................ 16 6.2 External Documentation .......................................................................................... 16

7 Appendix A, PD 8010-1 Mechanical Design Calculations .............................................. 17 7.1 Wall Thickness ........................................................................................................ 17 7.2 Expansion ............................................................................................................... 18 7.3 Upheaval Buckling .................................................................................................. 24 7.4 Specific Gravity (Bouyancy) .................................................................................... 25

8 Appendix B, API RP 1102 Uncased Road Crossing Assessment .................................. 26 9 Appendix C, DNV RP-J202 Wall Thickness Calculations ............................................... 30

9.1 Extract from Pressure Containment Calculations .................................................... 31

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Project Title: Kingsnorth Carbon Capture & Storage Project Page 2 of 31

Document Title: Onshore Pipeline Mechanical Design Report

Kingsnorth CCS Demonstration Project The information contained in this document (the Information) is provided in good fai th. E.ON UK plc, i ts subcontractors, subsidiaries, affi l iates, employees, advisers, and the Department of Energy and Cl imate Chan ge (DECC) make no representation or warranty as to the accuracy, rel iabi l i ty or completeness of the Information and neither E.ON UK plc nor any of i ts subcontractors, subsidiaries, affi l iates, employees, advisers or DECC shal l have any l iabil i ty whatsoever fo r any direct or indirect loss howsoever arising from the use of the Information by any party.

List of Tables Table 1.0-a Recommended Wall Thickness for Pressure Containment (ISO 3183 L450M) .........3 Table 1.0-b Recommended Wall Thickness for Pressure Containment (ISO 3183 L485M) .........3 Table 1.0-c Pipeline Anchor Forces...............................................................................................4 Table 1.0-d Concrete Coating Requirements ................................................................................4 Table 3.1-a Linepipe Properties .....................................................................................................7 Table 3.2-a Operating Data ...........................................................................................................8 Table 3.3-a Environmental Data ....................................................................................................8 Table 4.1-a Wall Thickness Results ...............................................................................................9 Table 4.2-a Circumferential Stress (DF 0.72) ............................................................................. 10 Table 4.2-b Circumferential Stress (DF 0.30) ............................................................................. 10 Table 4.3-a Longitudinal Operating Stress for Fully Restrained Pipeline (DF 0.72) ................... 11 Table 4.3-b Longitudinal Operating Stress for Fully Restrained Pipeline (DF 0.30) ................... 11 Table 4.4-a Equivalent Operating Stress for Fully Restrained Pipeline (DF 0.72) ..................... 11 Table 4.4-b Equivalent Operating Stress for Fully Restrained Pipeline (DF 0.30) ..................... 12 Table 4.5-a Anchor Force, Active Length and End Displacement (DF 0.72).............................. 12 Table 4.5-b Anchor Force, Active Length and End Displacement (DF 0.30).............................. 12 Table 4.6-a Continuous Concrete Coating Thickness ................................................................ 13 Table 4.7-a Relationship between Imperfection Height and Depth of Cover ............................. 13 Table 9.0-a DNV RP-J202 Wall Thickness Requirements (120barg) ......................................... 30 Table 9.0-b DNV RP-J202 Wall Thickness Requirements (150barg, base case) ...................... 30 Table 9.0-c DNV RP-J202 Wall Thickness Requirements (200barg) ......................................... 30

Table of Figures Figure 2-1-a Outline System Schematic..........................................................................................5

Table of Holds

HOLD Description Section

1 Maximum allowable operating pressure 3.2

2 Maximum operating temperature 3.2

3 Soil density 3.3

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Project Title: Kingsnorth Carbon Capture & Storage Project Page 3 of 31

Document Title: Onshore Pipeline Mechanical Design Report

Kingsnorth CCS Demonstration Project The information contained in this document (the Information) is provided in good fai th. E.ON UK plc, i ts subcontractors, subsidiaries, affi l iates, employees, advisers, and the Department of Energy and Cl imate Chan ge (DECC) make no representation or warranty as to the accuracy, rel iabi l i ty or completeness of the Information and neither E.ON UK plc nor any of i ts subcontractors, subsidiaries, affi l iates, employees, advisers or DECC shal l have any l iabil i ty whatsoever fo r any direct or indirect loss howsoever arising from the use of the Information by any party.

1 Summary This document addresses the methodology and calculations performed to determine the mechanical strength and stability of the onshore Kingsnorth CCS pipeline.

Mechanical calculations based on a linepipe material grade of ISO 3183 L450M (API 5L X65 equivalent) were carried out for the onshore section of the pipeline for design pressure options of 120barg, 150barg (base case) and 200barg with a design temperature of 70degC. Comparative wall thicknesses for pressure containment only have been conducted for a material grade of ISO 3183 L485M (API 5L X70 equivalent). Results for the base case option are shown in bold.

A new code which specifically addresses the transportation of CO2 has been developed and is available for general use, DNV RP-J202, Design and Operation of CO2 Pipelines [M7]. This code supplements the requirements of ISO 13623, Petroleum and Natural Gas Industries - Pipeline Transportation Systems [M8] and provides guidance on the determination of the required pipeline wall thickness as appropriate for the location class and fluid category. Neither code however, provides guidance on the determination of Building Proximity Distances (BPD) for differing design factors which is required for pipeline routing. DNV RP-J202 [M7] recommends the use of CO2 dispersion modelling, however, until such information or guidance is available, the calculations herein, as a minimum, meet the requirements of PD 8010-1, Code of Practice for Pipelines Part 1: Steel Pipelines on Land [M2]. This methodology should be reviewed during FEED.

To facilitate pigging operations, the pipeline is designed with a constant inside diameter (ID) such that the onshore pipeline is matched to the offshore pipeline and the outside diameter (OD) will vary accordingly. The recommended nominal wall thicknesses for pressure containment are shown in Tables 1.0-a and 1.0-b:

Description Unit Design Factor 0.72

(Standard Wall)

Design Factor 0.30 (Heavy Wall)

Design Pressure barg 120.0 150.0 200.0 120.0 150.0 200.0

Outside Diameter mm 914.0 920.4 921.6 967.4 982.2 1006.0

Inside Diameter mm 872.8 869.6 856.8 872.8 869.6 856.8

Wall Thickness mm 20.6 25.4 32.4 47.3 56.3 74.6

Table 1.0-a Recommended Wall Thickness for Pressure Containment (ISO 3183 L450M)

Description Unit Design Factor 0.72

(Standard Wall)

Design Factor 0.30 (Heavy Wall)

Design Pressure barg 120.0 150.0 200.0 120.0 150.0 200.0

Outside Diameter mm 914.0 917.2 920.2 960.4 974.2 998.2

Inside Diameter mm 872.8 869.6 860.0 872.8 869.6 860.0

Wall Thickness mm 20.6 23.8 30.1 43.8 52.3 69.1

Table 1.0-b Recommended Wall Thickness for Pressure Containment (ISO 3183 L485M)

The calculations for pressure containment show that for the 150barg design pressure option (base case), the use of ISO 3183 L485M (API 5L X70) will result in a wall thickness reduction of 1.5mm for a design factor of 0.72 and 4.0mm for a design factor of 0.30. Higher grade materials such as API 5L X80 and API 5L X100 could also be considered in order to reduce wall thickness however due consideration would need to be given to

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Document Title: Onshore Pipeline Mechanical Design Report

Kingsnorth CCS Demonstration Project The information contained in this document (the Information) is provided in good fai th. E.ON UK plc, i ts subcontractors, subsidiaries, affi l iates, employees, advisers, and the Department of Energy and Cl imate Chan ge (DECC) make no representation or warranty as to the accuracy, rel iabi l i ty or completeness of the Information and neither E.ON UK plc nor any of i ts subcontractors, subsidiaries, affi l iates, employees, advisers or DECC shal l have any l iabil i ty whatsoever fo r any direct or indirect loss howsoever arising from the use of the Information by any party.

material handling requirements during installation, weldability, pipe stability etc. The use of higher grade materials should be reviewed during FEED as part of the material selection process and cost benefit assessment.

Wall thickness requirements for pressure containment in accordance with DNV RP-J202 [M7] are presented in Appendix C. For the 150barg design pressure option (base case) there would be a wall thickness reduction of 1.6mm for the equivalent “standard wall” pipe and 24.5mm for the equivalent “heavy wall” pipe over those calculated in accordance with PD 8010-1 [M2] for a ISO 3183 L450M grade material.

In accordance with PD 8010-1 [M2], the proposed nominal wall thicknesses for the pipeline are sufficient to withstand the additional loads to which the pipeline will be subjected during installation and operation.

The force required to fully restrain the displacement of the pipeline at the maximum operating temperature of 40degC is presented in Table 1.0-c. Consideration should also be given to the inclusion of an expansion loop to accommodate the pipeline end expansion. This shall be confirmed during detailed design when a full stress analysis is performed.

Description Unit Design Factor 0.72 Design Factor 0.30

Design Pressure barg 120 150 200 120 150 200

Anchor Force kN 7,050 8,724 11,131 12,718 15,357 20,332

Active length m 190.0 229.0 285.0 301.0 343.0 429.0

End Displacement mm 55.8 67.3 84.7 67.6 78.8 96.5

Table 1.0-c Pipeline Anchor Forces

Buoyancy control, through the application of continuous concrete weight coating, will be required in areas of high water table, when the design factor is 0.72, because the pipeline is not heavy enough and will have a tendency to float when empty. The continuous concrete weight coating thickness was determined assuming a concrete with a density of 3040kg/m

3

and a ground water density of 1025kg/m3 (seawater).

Description Unit Design Factor 0.72 Design Factor 0.30

Design Pressure barg 120.0 150.0 200.0 120.0 150.0 200.0

Required Coating Thickness

mm 50.0 33.0 25.0 (1)

0.0 0.0 0.0

Table 1.0-d Concrete Coating Requirements

Note 1: For manufacturing purposes the minimum thickness of continuous concrete weight coating is limited to 25mm. An alternative would be to utilise intermittent set-on saddle weights.

No additional measures are needed to counter upheaval buckling.

A road crossing assessment performed in accordance with the requirements of API RP 1102 [M6], shows that the proposed wall thicknesses for each pressure case with a design factor of 0.3, satisfy the stress criteria for an uncased highway installation.

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Document Title: Onshore Pipeline Mechanical Design Report

Kingsnorth CCS Demonstration Project The information contained in this document (the Information) is provided in good fai th. E.ON UK plc, i ts subcontractors, subsidiaries, affi l iates, employees, advisers, and the Department of Energy and Cl imate Chan ge (DECC) make no representation or warranty as to the accuracy, rel iabi l i ty or completeness of the Information and neither E.ON UK plc nor any of i ts subcontractors, subsidiaries, affi l iates, employees, advisers or DECC shal l have any l iabil i ty whatsoever fo r any direct or indirect loss howsoever arising from the use of the Information by any party.

2 Introduction 2.1 Scope of Document

This document addresses the methodology and calculations performed to determine the mechanical strength and stability of the onshore section of the Kingsnorth CCS pipeline. The calculations, as a minimum, will meet the requirements of PD 8010-1, Code of Practice for Pipelines Part 1: Steel Pipelines on Land [M2].

An outline schematic of the pipeline system is shown in Figure 2.1-a. The limits of the onshore pipeline are defined as follows:

Pipeline landfall valve;

Kingsnorth Power Station CCS pig launcher.

Figure 2.1-a Outline System Schematic

The pipeline wall thickness shall be calculated for the selected material grade ISO 3183 L450M (API 5L X65 equivalent) as identified in the Basis of Design for Studies - Phase 1A [S1] based on internal design pressure. Design pressure options of 120barg, 150barg (base case) and 200barg have been considered.

The pipeline has also been assessed for strength and stability under the various loading conditions expected during installation and operation, as summarised below:

1. Circumferential stresses due to internal pressure are calculated;

2. Longitudinal tensile / compressive stresses due to internal pressure and thermal loading were determined for the restrained condition;

3. The Von Mises yield criterion has been used to determine the developed equivalent stress, relating the state of combined stress to the uniaxial state of stress;

4. The anchor force for the fully restrained pipeline and displacements at the pipeline free end if it was allowed to expand, together with the anchor (active) length of pipeline have also been determined;

5. The tendency for flotation in submerged soil conditions has been assessed;

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Document Title: Onshore Pipeline Mechanical Design Report

Kingsnorth CCS Demonstration Project The information contained in this document (the Information) is provided in good fai th. E.ON UK plc, i ts subcontractors, subsidiaries, affi l iates, employees, advisers, and the Department of Energy and Cl imate Chan ge (DECC) make no representation or warranty as to the accuracy, rel iabi l i ty or completeness of the Information and neither E.ON UK plc nor any of i ts subcontractors, subsidiaries, affi l iates, employees, advisers or DECC shal l have any l iabil i ty whatsoever fo r any direct or indirect loss howsoever arising from the use of the Information by any party.

6. The pipeline has also been assessed for propensity to upheaval buckling for several imperfection heights;

7. At road crossings the pipeline will be installed uncased. The stresses developing in the wall of the pipeline due to vehicle loading were analysed and assessed in accordance with API RP 1102, Steel Pipeline Crossing Railroads and Highways [M6].

2.2 Definitions

For the purpose of this document the following definitions shall apply:

Shall Indicates mandatory requirement

Should Indicates preferred course of action

May Indicates optional course of action

In the context of this document, the titles and definitions shall be specific when shown in upper case and non-specific when shown in lower case.

2.3 Abbreviations

Within this document, the following abbreviations are used:

3LPE 3 Layer Polyethylene

API American Petroleum Institute

ASME American Society of Mechanical Engineers

BPD Building Proximity Distance

CCS CO2 Capture and Storage

DF Design Factor

DNV Det Norske Veritas

FEED Front End Engineering Design

GOGC Genesis Oil and Gas Consultants

ID Inside Diameter

ISO International Organisation for Standardisation

MAOP Maximum Allowable Operating Pressure

OD Outside Diameter

SAWL Submerged Arc Weld Longitudinal

SMYS Specified Minimum Yield Strength

2.4 System of Units

Reference shall be made to the Overall Project Units, KCP-EEN-PCD-DPR-0001 [S5].

2.5 Cross References

Where cross-references to other parts of this document are made, the referenced section number is shown in brackets.

Other documents referenced by this report are listed in (5) and (6).

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Project Title: Kingsnorth Carbon Capture & Storage Project Page 7 of 31

Document Title: Onshore Pipeline Mechanical Design Report

Kingsnorth CCS Demonstration Project The information contained in this document (the Information) is provided in good fai th. E.ON UK plc, i ts subcontractors, subsidiaries, affi l iates, employees, advisers, and the Department of Energy and Cl imate Chan ge (DECC) make no representation or warranty as to the accuracy, rel iabi l i ty or completeness of the Information and neither E.ON UK plc nor any of i ts subcontractors, subsidiaries, affi l iates, employees, advisers or DECC shal l have any l iabil i ty whatsoever fo r any direct or indirect loss howsoever arising from the use of the Information by any party.

3 Design Data The data presented below and used for the analysis is extracted from the following project documents:

KCP-GNS-PCD-STU-0001 Basis of Design for Studies - Phase 1A [S1]

KCP-GNS-DES-DPR-0003 Offshore Pipeline Project Data [S2]

KCP-GNS-DES-DPR-0006 Onshore Pipeline Project Data [S3]

KCP-GNS-PLD-REP-0008 Wall Thickness Report - Phase 1A [S4]

3.1 Linepipe Properties

To facilitate pigging operations, the pipeline will have a constant ID. The wall thickness was initially selected for the offshore pipeline section [S4] where the pipe wall thickness and inside diameter were determined for a given nominal pipe outside diameter and steel grade.

The pipeline properties used for the wall thickness calculations are summarised in Table 3.1-a.

Description Unit Value

Defined Nominal Pipeline Diameter inch 36.0 (914.0mm)

Inside Diameter (1)

mm 872.8 869.6 856.8

Manufacturing Tolerance mm 1.5

Corrosion Allowance mm 1.5

Material Grade SAWL, ISO 3183 L450M

Specified Minimum Yield Strength (SMYS) MPa 450 / 438 (2)

Steel Density kg/m3 7850

Young’s Modulus MPa 207000

Table 3.1-a Linepipe Properties

Note 1: ID for design pressure options of 120barg, 150barg (base case) and 200barg respectively.

Note 2: De-rated SMYS for 70degC design temperature in accordance with the requirements of DNV OS-F101 [M4].

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Project Title: Kingsnorth Carbon Capture & Storage Project Page 8 of 31

Document Title: Onshore Pipeline Mechanical Design Report

Kingsnorth CCS Demonstration Project The information contained in this document (the Information) is provided in good fai th. E.ON UK plc, i ts subcontractors, subsidiaries, affi l iates, employees, advisers, and the Department of Energy and Cl imate Chan ge (DECC) make no representation or warranty as to the accuracy, rel iabi l i ty or completeness of the Information and neither E.ON UK plc nor any of i ts subcontractors, subsidiaries, affi l iates, employees, advisers or DECC shal l have any l iabil i ty whatsoever fo r any direct or indirect loss howsoever arising from the use of the Information by any party.

3.2 Operating Data

The pipeline operating data used for the analysis are summarised in Table 3.2-a below.

Description Unit Value

Fluid Category (1)

E

Design Pressure barg 120 150 200

Maximum Allowable Operating Pressure (MAOP)

barg HOLD1 HOLD1 HOLD1

Design Temperature degC 70.0

Maximum Operating Temperature degC 40.0 (HOLD2)

Contents Density – Dense Phase (2)

kg/m3 597.13 669.38 742.26

Table 3.2-a Operating Data

Note 1: In accordance with the Basis of Design for Studies – Phase 1A [S1], the dense phase CO2 anticipated to be produced from the Kingsnorth power station will be classified as Category E substance under PD 8010-1 [M2] toxic fluids that are gases at ambient temperature and atmospheric pressure conditions and are conveyed as gases and / or liquids.

Note 2: Contents density at maximum inlet temperature of 40degC (dense phase).

3.3 Environmental Data

The environmental data used for the analysis is summarised in Table 3.3-a.

Description Unit Value

Ground Water Density kg/m3 1025

Soil Density kg/m3 1950 (HOLD3)

Installation Temperature degC 11.0

Table 3.3-a Environmental Data

3.4 External Corrosion Protection

The buried sections of the onshore pipeline shall be protected against external corrosion using an appropriate anti-corrosion coating. Typical properties for a 3 layer polyethylene (3LPE) coating are presented in Table 3.4-a.

Coating Type Nominal Thickness

mm

Density

kg/cu.m

Thermal Conductivity

W/mK

3LPE 3.2 950 0.35

Table 3.4-a Anti-Corrosion Coating Properties

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Document Title: Onshore Pipeline Mechanical Design Report

Kingsnorth CCS Demonstration Project The information contained in this document (the Information) is provided in good fai th. E.ON UK plc, i ts subcontractors, subsidiaries, affi l iates, employees, advisers, and the Department of Energy and Cl imate Chan ge (DECC) make no representation or warranty as to the accuracy, rel iabi l i ty or completeness of the Information and neither E.ON UK plc nor any of i ts subcontractors, subsidiaries, affi l iates, employees, advisers or DECC shal l have any l iabil i ty whatsoever fo r any direct or indirect loss howsoever arising from the use of the Information by any party.

4 Mechanical Calculations Mechanical design calculations have been carried out for the onshore sections of the buried Kingsnorth CCS pipeline. The purpose of the mechanical design calculations is to verify the wall thickness of the pipeline and to ascertain the strength and stability of the pipeline under the various loading conditions envisaged during installation and operation. Calculations for the 150barg design pressure option (base case) are included in Appendix A.

4.1 Wall Thickness Calculations

The pipeline wall thickness has been determined in accordance with Clause 6.2.2.1 of PD 8010-1 [M2]. This clause requires that the wall thickness shall be capable of withstanding the load exerted on the wall of the pipeline by the fluid internal pressure. The resulting circumferential (hoop) stress shall not exceed the specified minimum yield stress of the pipe material by a factor applicable to the installation location. Design factors for the onshore pipeline will depend on the population density. For pipelines intended to convey category E fluids, the design factor should under normal circumstances not exceed 0.72 in Class 1 locations (population density less than 2.5 persons per hectare). In Class 2 locations (population density greater than 2.5 persons per hectare) a design factor of 0.3 shall apply. A design factor of 0.3 shall also apply at major / minor road crossings, railway crossings and at fabricated assemblies ie pig traps, block valves, subject to a risk assessment. The corrosion allowance and manufacturing tolerance is added to the calculated wall thickness to determine the nominal wall thickness.

In accordance with standard industry practice, the outside diameter to wall thickness ratio (D/t), where t is the minimum wall thickness (excluding corrosion allowance and manufacturing tolerance), should not exceed 96 unless it can be demonstrated that higher values are not detrimental to the construction and in-situ integrity of the pipeline.

As discussed in (3.1), to facilitate pigging operations, the pipeline will have a constant ID. For ease of analysis, the wall thickness is selected initially for the offshore pipeline section where the pipe wall thickness and inside diameter are determined for a given nominal pipe outside diameter and steel grade. The inside diameter of the pipeline is then maintained for the remaining sections.

Description Unit Design Factor 0.72 Design Factor 0.30

Design Pressure barg 120.0 150.0 200.0 120.0 150.0 200.0

Required Inside Diameter

mm 872.8 869.6 856.8 872.8 869.6 856.8

Calculated Nominal Wall Thickness

mm 20.39 24.89 32.22 47.17 56.20 74.53

Selected Wall Thickness

mm 20.6 25.4 32.4 47.3 56.3 74.6

Outside Diameter mm 914.0 920.4 921.6 967.4 982.2 1006.0

Table 4.1-a Wall Thickness Results

The nominal wall thickness is also assessed for the capacity to withstand additional loading to which the pipeline will be subjected during installation and operation. In accordance with Clause 6.4.2.5 of PD 8010-1 [M2], the resulting stresses are then combined by the Von Mises yield criterion in the form of an equivalent stress. The value of the resulting equivalent stress shall not exceed the allowable equivalent stress as defined in Clause

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Document Title: Onshore Pipeline Mechanical Design Report

Kingsnorth CCS Demonstration Project The information contained in this document (the Information) is provided in good fai th. E.ON UK plc, i ts subcontractors, subsidiaries, affi l iates, employees, advisers, and the Department of Energy and Cl imate Chan ge (DECC) make no representation or warranty as to the accuracy, rel iabi l i ty or completeness of the Information and neither E.ON UK plc nor any of i ts subcontractors, subsidiaries, affi l iates, employees, advisers or DECC shal l have any l iabil i ty whatsoever fo r any direct or indirect loss howsoever arising from the use of the Information by any party.

6.4.3.2 of PD 8010-1 [M2]. The stress calculations for the operational phase have been carried out using the pipe nominal wall thickness.

4.2 Circumferential Stresses

Circumferential stresses are developed in the wall of the pipeline as a result of hydrostatic pressure testing and operational conditions. These stresses are calculated together with other stresses and included in the overall stress assessment of the pipeline for the installation and operational conditions to which the pipeline will be subjected.

Internal pressure will produce circumferential tensile stresses in the wall of the pipeline (hoop stress). The Barlow equation as defined in Clause 6.4.2.1 of PD 8010-1 [M2] was used to calculate the stresses for the selected wall thickness and the results are shown in Tables 4.2.2-a and 4.2.2-b. For the operating condition the design pressure is used. For the hydrostatic pressure test the internal pressure is taken as 150% of the design pressure.

Description Unit Design Factor 0.72

Design Pressure barg 120 150 200

Circumferential Stress due to Internal Pressure (Operating)

N/mm2 266.2 271.8 284.4

Circumferential Stress due to Internal Pressure (Hydrostatic test)

N/mm2 399.3 407.7 426.7

Table 4.2-a Circumferential Stress (DF 0.72)

Description Unit Design Factor 0.30

Design Pressure barg 120 150 200

Circumferential Stress due to Internal Pressure (Operating)

N/mm2 117.0 123.8 125.7

Circumferential Stress due to Internal Pressure (Hydrostatic test)

N/mm2 175.5 185.7 188.5

Table 4.2-b Circumferential Stress (DF 0.30)

4.3 Longitudinal Stresses for Fully Restrained Pipeline

Pipelines tend to expand or contract in the longitudinal direction under the effect of internal pressure and thermal expansion. Internal pressure results in the pipe contracting in the longitudinal direction due to Poisson’s Ratio effect. An increase in pipe temperature compared to the temperature at which the pipeline was installed causes the pipe to expand due to the effect of linear thermal expansion for the pipe material. It follows that a decrease in temperature below the installation temperature will cause the pipe to reduce in length. For buried pipelines, the surrounding soil friction forces will resist this longitudinal expansion/contraction and for relatively long straight sections of pipeline the surrounding soil will manage to exercise full restraint on the pipeline until there is zero strain in the pipeline. The restraint of the soil against the tendency of the pipe to shrink because of the internal pressure effect produces longitudinal tensile stress in the wall of the pipe. The soil restraint against the thermally induced tendency to elongate the pipe will cause longitudinal compressive stresses. The resultant longitudinal stress will be the algebraic sum of these two longitudinal stresses. The thermally induced longitudinal stress for the operating case was calculated using an installation temperature of 11degC and the design temperature of 70degC. A lower installation temperature will lead to a higher longitudinal compressive

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stress. Tensile longitudinal stress in the presence of tensile circumferential stress is not detrimental to the strength of the pipe as long as it is less in value than the circumferential tensile stress. It is the compressive longitudinal stress in the presence of tensile circumferential stress, which restricts the strength capacity of the pipe.

The calculated longitudinal stresses for a fully restrained pipeline are shown in Tables 4.3-a and 4.3-b. A negative longitudinal stress is compressive. The calculated equivalent stress and the minimum allowable radius of curvature for a fully restrained line are shown in Tables 4.4-a and 4.4-b.

Description Unit Design Factor 0.72

Design Pressure barg 120 150 200

Total Longitudinal Stress N/mm2 -99.5 -107.9 -111.5

Table 4.3-a Longitudinal Operating Stress for Fully Restrained Pipeline (DF 0.72)

Description Unit Design Factor 0.30

Design Pressure barg 120 150 200

Total Longitudinal Stress N/mm2 -159.1 -160.5 -163.7

Table 4.3-b Longitudinal Operating Stress for Fully Restrained Pipeline (DF 0.30)

4.4 Equivalent Stress for Fully Restrained Pipeline

After determining the total circumferential and total longitudinal stresses acting in the wall of the pipeline (for fully restrained conditions), the resulting equivalent stress is calculated using the Von Mises yield criterion. The resulting equivalent stress should not exceed the maximum equivalent stress which is 90% of the material SMYS. The difference between the calculated equivalent stress and the maximum allowable equivalent stress can be allocated as available longitudinal stress which can be used to accommodate longitudinal bending stresses induced in the wall of the pipeline as a result of gentle terrain undulations along the pipeline route. Any undulation or horizontal curve along the pipeline route which will have a radius of curvature larger than the calculated minimum radius of curvature can be accommodated within the elastic range of the pipe material. Undulations or other curves along the pipeline route that require radii of curvature less than the calculated elastic minimum radius of curvature will have to be made with the use of hot formed bends or cold formed field bends as appropriate. Hot formed bends (shop fabricated) shall have a minimum radius of 5D.

The calculated equivalent stress is shown in Tables 4.4-a and 4.4-b.

Description Unit Design Factor 0.72

Design Pressure barg 120 150 200

Max Allowable Equivalent Stress N/mm2 394.2

Equivalent Stress N/mm2 327.5 338.9 353.6

Table 4.4-a Equivalent Operating Stress for Fully Restrained Pipeline (DF 0.72)

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Description Unit Design Factor 0.30

Design Pressure barg 120 150 200

Max Allowable Equivalent Stress N/mm2 394.2

Equivalent Stress N/mm2 204.7 246.9 251.3

Table 4.4-b Equivalent Operating Stress for Fully Restrained Pipeline (DF 0.30)

4.5 Anchor Force and Displacement, Partly Restrained Pipeline

At termination points, the soil can no longer maintain full restraint on the buried sections of pipeline upstream of the termination point. These sections are identified as partly restrained sections. Sections upstream of termination points, the displacement is in the direction of the termination point. If the pipeline displacements at these locations are unacceptable or the stresses at the bends become unacceptably high, the displacements can be prevented by installing anchor blocks on the straight section of the pipeline just prior to the termination point. The force required to fully restrain the displacement of the pipeline at these locations is defined as the anchor force. The length of the partly restrained sections is dependant on the pipe and soil interaction. The length of the partly restrained moving section, called the active length is determined as a function of the anchor force and the friction force applied by the surrounding soil on the pipeline. Here, the anchor force is defined as the potential force that would be required to restrain the pipeline, since anchoring the pipeline will eliminate displacement. The friction force will depend on the backfill soil load, the pipe parameters and operating conditions.

For the thermally induced loads a maximum operating temperature of 40degC has been used in preference to the design temperature of 70degC as this most closely represents the continuous as installed condition. It is assumed that excursions above 40degC would be under fault conditions and only for a short period of time.

Anchor force, active length, end displacement have been determined for the operating load case in the un-corroded state as required by Clause 6.4.2.2 of PD 8010-1 [M2].

The results are shown in Tables 4.5-a and 4.5-b.

Description Unit Design Factor 0.72

Design Pressure barg 120 150 200

Anchor Force kN 7,050 8,724 11,131

Active Length m 190.0 229.0 285.0

End Displacement (1)

mm 55.8 67.3 84.7

Table 4.5-a Anchor Force, Active Length and End Displacement (DF 0.72)

Description Unit Design Factor 0.30

Design Pressure barg 120 150 200

Anchor Force kN 12,718 15,357 20,332

Active Length m 301.0 343.0 429.0

End Displacement (1)

mm 67.6 78.8 96.5

Table 4.5-b Anchor Force, Active Length and End Displacement (DF 0.30)

Note 1: Assumes that the pipeline is not anchored, long and in dry conditions.

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Kingsnorth CCS Demonstration Project The information contained in this document (the Information) is provided in good fai th. E.ON UK plc, i ts subcontractors, subsidiaries, affi l iates, employees, advisers, and the Department of Energy and Cl imate Chan ge (DECC) make no representation or warranty as to the accuracy, rel iabi l i ty or completeness of the Information and neither E.ON UK plc nor any of i ts subcontractors, subsidiaries, affi l iates, employees, advisers or DECC shal l have any l iabil i ty whatsoever fo r any direct or indirect loss howsoever arising from the use of the Information by any party.

4.6 Anti-buoyancy Assessment

The pipeline has been assessed for the possibility of flotation in areas of high water table with a density of 1025kg/m3 (seawater). The results show that the pipeline in the empty condition may experience flotation if it is not provided with additional weighting. The continuous concrete coating thickness was determined using concrete with a unit weight of 3040kg/m3. A safety factor of 1.1 is employed.

The required continuous concrete coating thicknesses are summarised in Table 4.6-a.

Description Unit Design Factor 0.72 Design Factor 0.30

Design Pressure barg 120.0 150.0 200.0 120.0 150.0 200.0

Calculated Coating Thickness

mm 49.4 33.2 7.6 (1)

-43.5 (2)

-78.6 (2)

-159.1 (2)

Table 4.6-a Continuous Concrete Coating Thickness

Note 1: For manufacturing purposes the minimum thickness of continuous concrete weight coating is limited to 25mm. Intermediate set-on saddle weights could be employed as an alternative.

Note 2: A negative result indicates that concrete coating is not required and there is sufficient weight in the pipeline to resist floatation.

4.7 Upheaval Buckling

The guideline method from 1990 OTC paper No. 6335 [S6] has been used to assess the propensity of the pipeline for upheaval buckling. Imperfections of up to 0.3 m height were evaluated and the results presented in Table 4.7-a show that the pipeline is unlikely to experience upheaval buckling for the cases considered. The effects of continuous concrete weight coating are ignored.

Description Unit Required Depth of Cover (m)

Design Factor 0.72 Design Factor 0.30

Design Pressure barg 120.0 150.0 200.0 120.0 150.0 200.0

Wall Thickness mm 20.6 25.4 32.4 47.3 56.3 74.6

Imperfection Height

0.05

m

-0.33 -0.38 -0.45 -0.63 -0.73 -0.94

0.10 -0.29 -0.33 -0.39 -0.58 -0.67 -0.86

0.20 -0.24 -0.28 -0.32 -0.49 -0.56 -0.71

0.30 -0.21 -0.23 -0.26 -0.42 -0.48 -0.61

Table 4.7-a Relationship between Imperfection Height and Depth of Cover

The negative sign in front of the required depth of cover indicates that pipeline does not require burial to counter upheaval buckling.

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Kingsnorth CCS Demonstration Project The information contained in this document (the Information) is provided in good fai th. E.ON UK plc, i ts subcontractors, subsidiaries, affi l iates, employees, advisers, and the Department of Energy and Cl imate Chan ge (DECC) make no representation or warranty as to the accuracy, rel iabi l i ty or completeness of the Information and neither E.ON UK plc nor any of i ts subcontractors, subsidiaries, affi l iates, employees, advisers or DECC shal l have any l iabil i ty whatsoever fo r any direct or indirect loss howsoever arising from the use of the Information by any party.

4.8 API RP 1102 Road Crossing Assessment

To ensure safe operation, the stresses affecting the pipeline at a road crossing must be accounted for, which includes both circumferential and longitudinal stresses. The recommended design procedure for determining the acceptability of the stresses is given in API RP 1102, Steel pipeline crossing railroads and highways [M6].

The pipeline will be subjected to both internal load due to pressure and external loads from earth forces (dead load) and highway traffic (live load).

Other loads may be present as a result of temperature fluctuations caused by changes in season; longitudinal tension due to end effects; fluctuations associated with pipeline operating conditions; unusual surface loads associated with the movement of specialised equipment and ground deformation as a result of shrinking and swelling soils, local instability etc. Pipe stresses as a result of temperature fluctuations can be included in the analysis; all other loads are a result of special conditions. Loads of this nature are site specific and as such have not been included as part of this assessment.

The assessment calculations shown in Appendix B, show that the proposed wall thicknesses for a design factor of 0.3 as presented in Table 4.1-a, satisfy the stress criteria of API RP 1102 [M6] for uncased installation at an unpaved highway.

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Kingsnorth CCS Demonstration Project The information contained in this document (the Information) is provided in good fai th. E.ON UK plc, i ts subcontractors, subsidiaries, affi l iates, employees, advisers, and the Department of Energy and Cl imate Chan ge (DECC) make no representation or warranty as to the accuracy, rel iabi l i ty or completeness of the Information and neither E.ON UK plc nor any of i ts subcontractors, subsidiaries, affi l iates, employees, advisers or DECC shal l have any l iabil i ty whatsoever fo r any direct or indirect loss howsoever arising from the use of the Information by any party.

5 Mandatory References The design, fabrication and construction of the pipeline system shall be in accordance with the latest revisions of the following specifications, codes and standards unless stated otherwise.

5.1 Codes and Standards

[M1] BS EN 14161 Petroleum and Natural Gas Industries Pipeline Transportation Systems;

[M2] PD 8010-1 Code of Practice for Pipelines - Part 1: Steel Pipelines on Land;

[M3] ISO 3183 / API 5L Petroleum and Natural Gas Industries - Steel Pipe for Pipeline Transportation Systems;

[M4] DNV OS-F101 Submarine Pipeline Systems;

[M5] ASME B31.4 Pipeline Transportation Systems for Liquid Hydrocarbons & Other Liquids;

[M6] API RP 1102 Steel pipeline crossing railroads and highways;

[M7] DNV-RP-J202 Design and Operation of CO2 Pipelines;

[M8] ISO 13623 Petroleum & Natural Gas Industries - Pipeline Transportation Systems;

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Kingsnorth CCS Demonstration Project The information contained in this document (the Information) is provided in good fai th. E.ON UK plc, i ts subcontractors, subsidiaries, affi l iates, employees, advisers, and the Department of Energy and Cl imate Chan ge (DECC) make no representation or warranty as to the accuracy, rel iabi l i ty or completeness of the Information and neither E.ON UK plc nor any of i ts subcontractors, subsidiaries, affi l iates, employees, advisers or DECC shal l have any l iabil i ty whatsoever fo r any direct or indirect loss howsoever arising from the use of the Information by any party.

6 Supporting References 6.1 Project Documentation

[S1] KCP-GNS-PCD-STU-0001 Basis of Design for Studies - Phase 1A;

[S2] KCP-GNS-DES-DPR-0003 Offshore Pipeline Project Data;

[S3] KCP-GNS-DES-DPR-0006 Onshore Pipeline Project Data;

[S4] KCP-GNS-PLD-REP-0008 Wall Thickness Report - Phase 1A;

[S5] KCP-EEN-PCD-DPR-0001 Overall Project Units;

6.2 External Documentation

[S6] OTC Paper 6335, 1990 Design of Submarine Pipelines Against Upheaval Buckling;

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Kingsnorth CCS Demonstration Project The information contained in this document (the Information) is provided in good fai th. E.ON UK plc, i ts subcontractors, subsidiaries, affi l iates, employees, advisers, and the Department of Energy and Cl imate Chan ge (DECC) make no representation or warranty as to the accuracy, rel iabi l i ty or completeness of the Information and neither E.ON UK plc nor any of i ts subcontractors, subsidiaries, affi l iates, employees, advisers or DECC shal l have any l iabil i ty whatsoever fo r any direct or indirect loss howsoever arising from the use of the Information by any party.

7 Appendix A, PD 8010-1 Mechanical Design Calculations The extracts from the mechanical design calculations for the 150barg design pressure option are presented below:

7.1 Wall Thickness

Genesis Oil and Gas Ltd CALCULATION SHEET

Client By Checked Page of

E.ON NJ AA

Project Date Rev. Ref.

Kingsnorth CCS - Onshore Pipeline 22/07/2010 1

Subject

PD 8010 Wall Thickness Verification

Parameter Units PD 8010 Pressure Containment

BASE CASE BASE CASE BASE CASE BASE CASEAPI 5L X65 API 5L X65 API 5L X70 API 5L X70

150barg 150barg 150barg 150bargInput 0.72 DF 0.30 DF 0.72 DF 0.30 DF

Wall Thickness DesignOutside Diameter mm 920.4 982.2 917.2 974.2

SMYS derated @ operating Tº MPa 438 438 473 473

Choose Mill Tolerance in mm or % - mm mm mm mm

Mill Tolerance % 12.5% 12.5% 12.5% 12.5%

Mill Tolerance mm 1.5 1.5 1.5 1.5Corrosion Allowance mm 1.5 1.5 1.5 1.5

Design Pressure barg 150 150 150 150

@ Elevation (rel to LAT) m 0 0 0 0

Contents Density kg/m3 669.4 669.4 669.4 669.4

Water Depth (LAT) m 0 0 0 0

Minimum Water Depth m 0 0 0 0

Seawater Density kg/m3 0 0 0 0

Hoop Stress Design Factor % 72% 30% 72% 30%

Internal Pressure Pi barg 150.0 150.0 150.0 150.0

Min External Pressure Po barg 0.0 0.0 0.0 0.0

Thin Wall Thickness

Min Wall Thickness mm 21.9 56.1 20.2 51.5

D/t Ratio - 42.0 17.5 45.4 18.9

WT+CA+MT mm 24.89 59.06 23.20 54.49

Thick Wall Thickness

Internal diameter m 0.8776 0.8758 0.8777 0.8761

Min Wall Thickness mm 21.4 53.2 19.8 49.0

D/t Ratio - 43.0 18.5 46.4 19.9

WT+CA+MT mm 24.39 56.20 22.77 52.04

Hydrotest DesignSelected API Size mm 25.40 56.30 23.80 52.30

Inside diameter mm 869.60 869.60 869.60 869.60

Select WT Type - Thin Wall Thickness Thick Wall Thickness Thin Wall ThicknessThick Wall Thickness

SMYS @ ambiant Tº MPa 450 450 485 485

Contents Density for Hydrotest kg/m3 1025 1025 1025 1025

Hoop Stress Design Factor % 90% 90% 90% 90%

Internal Diameter - Mill Tol mm 872.6 872.6 872.6 872.6

Hydrotest Pressure (90% σh) barg 210.3 477.0 212.3 478.8

Hydrotest Pressure (1.5 x DP) barg 225 225 225 225

Selected Hydrotest Pressure barg 210 225 212 225

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7.2 Expansion

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7.3 Upheaval Buckling

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7.4 Specific Gravity (Bouyancy)

Pipe OD mm 920.4

Wall thickness mm 25.40

Steel density kg/m3 7850

Seawater density kg/m3 1025

Contents Density kg/m3 669.38

Density Thk

(kg/m3) mm

Layer 1:3LPE 950 3.20

Layer 2: Concrete 3040 33.15

Layer 3:Solid PP 900 0.00

Layer 4: PP Foam 740 0.00

Layer 5: Solid PP 900 0.00

Overall OD 993.0968

ID OD Area

m m m2 kg/m N/m

Pipe 0 8696 0 9204 0 0714 560 630 5499 780

Contents 0 8696 0 5939 397 5591 3900 055

Water 0 8696 0 5939 608 7694 5972 028

Option 1Layer 1 0 9204 0 9268 0 0093 8 821 86 532

Layer 2 0 9268 0 99309682 0 1000 303 902 2981 282

Layer 3 0 9930968 0 99309682 0 0000 0 000 0 000

Layer 4 0 9930968 0 99309682 0 0000 0 000 0 000

Layer 5 0 9930968 0 99309682 0 0000 0 000 0 000

Dry weight empty 873 353 8567 594

Dry weight pipe + contents 1270 912 12467 648

Bouyancy force 793 957 7788 717

Submerged weight pipe empty 79 396 778 876

Submerged weight pipe + water 688 166 6750 904

Submerged weight pipe + contents 476.955 4678 931

SG submergedempty 1 100

water 1 867

contents 1 601

Weight/m

Pipe OD mm 982.2

Wall thickness mm 56.30

Steel density kg/m3 7850

Seawater density kg/m3 1025

Contents Density kg/m3 669 38

Density Thk

(kg/m3) mm

Layer 1:3LPE 950 3.20

Layer 2: Concrete 3040 -78.54

Layer 3 Solid PP 900 0.00

Layer 4: PP Foam 740 0.00

Layer 5: Solid PP 900 0.00

Overall OD 831.5175

ID OD Area

m m m2 kg/m N/m

Pipe 0 8696 0 9822 0 1638 1285 559 12611 334

Contents 0 8696 0 5939 397 5591 3900 055

Water 0 8696 0 5939 608 7694 5972 028

Option 1Layer 1 0 9822 0 9886 0 0099 9 411 92 322

Layer 2 0 9886 0 83151747 -0 2246 -682 638 -6696 684

Layer 3 0 8315175 0 83151747 0 0000 0 000 0 000

Layer 4 0 8315175 0 83151747 0 0000 0 000 0 000

Layer 5 0 8315175 0 83151747 0 0000 0 000 0 000

Dry weight empty 612 331 6006 972

Dry weight pipe + contents 1009 891 9907 027

Bouyancy force 556 617 5460 413

Submerged weight pipe empty 55 714 546 559

Submerged weight pipe + water 664 484 6518 587

Submerged weight pipe + contents 453.274 4446 613

SG submergedempty 1 100

water 2 194

contents 1 814

Weight/m

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Kingsnorth CCS Demonstration Project The information contained in this document (the Information) is provided in good fai th. E.ON UK plc, i ts subcontractors, subsidiaries, affi l iates, employees, advisers, and the Department of Energy and Cl imate Change (DECC) make no representation or warranty as to the accuracy, rel iabi l i ty or completeness of the Information and neither E.ON UK plc nor any of i ts subcontractors, subsidiaries, affi l iates, employees, advisers or DECC shal l have any l iabil i ty whatsoever for any direct or indirect loss howsoever arising from the use of the Information by any party.

8 Appendix B, API RP 1102 Uncased Road Crossing Assessment

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Kingsnorth CCS Demonstration Project The information contained in this document (the Information) is provided in good fai th. E.ON UK plc, i ts subcontractors, subsidiaries, affi l iates, employees, advisers, and the Department of Energy and Cl imate Chan ge (DECC) make no representation or warranty as to the accuracy, rel iabi l i ty or completeness of the Information and neither E.ON UK plc nor any of i ts subcontractors, subsidiaries, affi l iates, employees, advisers or DECC shal l have any l iabil i ty whatsoever fo r any direct or indirect loss howsoever arising from the use of the Information by any party.

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Document Title: Onshore Pipeline Mechanical Design Report

Kingsnorth CCS Demonstration Project The information contained in this document (the Information) is provided in good fai th. E.ON UK plc, i ts subcontractors, subsidiaries, affi l iates, employees, advisers, and the Department of Energy and Cl imate Chan ge (DECC) make no representation or warranty as to the accuracy, rel iabi l i ty or completeness of the Information and neither E.ON UK plc nor any of i ts subcontractors, subsidiaries, affi l iates, employees, advisers or DECC shal l have any l iabil i ty whatsoever fo r any direct or indirect loss howsoever arising from the use of the Information by any party.

Page 29: 6.57 Onshore Pipeline Mechanical Design Report

KCP-GNS-PLD-DRP-0004 Rev: 03

Project Title: Kingsnorth Carbon Capture & Storage Project Page 29 of 31

Document Title: Onshore Pipeline Mechanical Design Report

Kingsnorth CCS Demonstration Project The information contained in this document (the Information) is provided in good fai th. E.ON UK plc, i ts subcontractors, subsidiaries, affi l iates, employees, advisers, and the Department of Energy and Cl imate Chan ge (DECC) make no representation or warranty as to the accuracy, rel iabi l i ty or completeness of the Information and neither E.ON UK plc nor any of i ts subcontractors, subsidiaries, affi l iates, employees, advisers or DECC shal l have any l iabil i ty whatsoever fo r any direct or indirect loss howsoever arising from the use of the Information by any party.

Page 30: 6.57 Onshore Pipeline Mechanical Design Report

KCP-GNS-PLD-DRP-0004 Rev: 03

Project Title: Kingsnorth Carbon Capture & Storage Project Page 30 of 31

Document Title: Onshore Pipeline Mechanical Design Report

Kingsnorth CCS Demonstration Project The information contained in this document (the Information) is provided in good fai th. E.ON UK plc, i ts subcontractors, subsidiaries, affi l iates, employees, advisers, and the Department of Energy and Cl imate Chan ge (DECC) make no representation or warranty as to the accuracy, rel iabi l i ty or completeness of the Information and neither E.ON UK plc nor any of i ts subcontractors, subsidiaries, affi l iates, employees, advisers or DECC shal l have any l iabil i ty whatsoever fo r any direct or indirect loss howsoever arising from the use of the Information by any party.

9 Appendix C, DNV RP-J202 Wall Thickness Calculations The following presents the wall thicknesses as determined in accordance with Clause 5.4 of DNV RP-J202 [M17] for a ISO 3183 L450M grade material. The results presented in Tables 9.0-a, 9.0-b and 9.0-c are for comparative purposes only and do not form part of the mechanical design detailed herein.

This clause requires that the wall thickness shall be capable of withstanding the load exerted on the wall of the pipeline by the fluid pressure. The resulting circumferential (hoop) stress shall not exceed the specified minimum yield stress of the pipe material by a factor applicable to the installation location as defined in Table 5-2 of DNV RP-J202 [M17]. The analysis considers design factors 0.77, 0.67 and 0.55 which are applicable to location classes 2, 3 and 4 respectively as defined in Table B.2 of ISO 13623 [M18].

As discussed in (3.1), to facilitate pigging operations the pipeline is designed with a constant ID which matches the offshore pipeline section.

Description Unit Value

Design Factor 0.77 0.67 0.55

Inside Diameter mm 872.8

Calculated Nominal Wall Thickness mm 18.98 21.38 25.52

Selected Wall Thickness mm 20.60 22.20 27.00

Outside Diameter mm 914.0 917.20 926.80

Table 9.0-a DNV RP-J202 Wall Thickness Requirements (120barg)

Description Unit Value

Design Factor 0.77 0.67 0.55

Inside Diameter mm 869.6

Calculated Nominal Wall Thickness mm 22.95 26.02 31.18

Selected Wall Thickness mm 23.80 27.00 31.80

Outside Diameter mm 917.20 923.60 933.20

Table 9.0-b DNV RP-J202 Wall Thickness Requirements (150barg, base case)

Description Unit Value

Design Factor 0.77 0.67 0.55

Inside Diameter mm 856.8

Calculated Nominal Wall Thickness mm 29.41 33.45 40.38

Selected Wall Thickness mm 30.20 33.60 40.50

Outside Diameter mm 917.20 924.00 937.80

Table 9.0-c DNV RP-J202 Wall Thickness Requirements (200barg)

Page 31: 6.57 Onshore Pipeline Mechanical Design Report

KCP-GNS-PLD-DRP-0004 Rev: 03

Project Title: Kingsnorth Carbon Capture & Storage Project Page 31 of 31

Document Title: Onshore Pipeline Mechanical Design Report

Kingsnorth CCS Demonstration Project The information contained in this document (the Information) is provided in good fai th. E.ON UK plc, i ts subcontractors, subsidiaries, affi l iates, employees, advisers, and the Department of Energy and Cl imate Chan ge (DECC) make no representation or warranty as to the accuracy, rel iabi l i ty or completeness of the Information and neither E.ON UK plc nor any of i ts subcontractors, subsidiaries, affi l iates, employees, advisers or DECC shal l have any l iabil i ty whatsoever fo r any direct or indirect loss howsoever arising from the use of the Information by any party.

9.1 Extract from Pressure Containment Calculations

The pressure containment calculations for the 150barg design pressure option (base case) are presented below:

ISO 13623 Pipeline calculations Operating

Internal pressure P 15.00 N/mm2

SMYS S 438.00 N/mm2

Corrosion allowance Ca 1.50 mm

Manufacturing tolerance mt 1.50 mm

Design factor Fh 0.77

Outside diameter D 917.20 mm

Specified minimum wall thickness tmin 19.95 mm

Nominal wall thickness tnom 22.95 mm

Selected wall thickness t 23.80 mm

Minimum wall thickness t' 20.80 mm

D/t Ratio 44.10

Inside diameter d 869.60 mm

ISO 13623 Pipeline calculations Operating

Internal pressure P 15.00 N/mm2

SMYS S 438.00 N/mm2

Corrosion allowance Ca 1.50 mm

Manufacturing tolerance mt 1.50 mm

Design factor Fh 0.67

Outside diameter D 923.60 mm

Specified minimum wall thickness tmin 23.02 mm

Nominal wall thickness tnom 26.02 mm

Selected wall thickness t 27.00 mm

Minimum wall thickness t' 24.00 mm

D/t Ratio 38.48

Inside diameter d 869.60 mm

ISO 13623 Pipeline calculations Operating

Internal pressure P 15.00 N/mm2

SMYS S 438.00 N/mm2

Corrosion allowance Ca 1.50 mm

Manufacturing tolerance mt 1.50 mm

Design factor Fh 0.55

Outside diameter D 933.20 mm

Specified minimum wall thickness tmin 28.18 mm

Nominal wall thickness tnom 31.18 mm

Selected wall thickness t 31.80 mm

Minimum wall thickness t' 28.80 mm

D/t Ratio 32.40

Inside diameter d 869.60 mm