D05 Leif_DNV_Changes in DNV-OS-F101 2012.pdf

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Sigbjørn Røneid, Leif Collberg, Sondre Løkenand Steinar Bjerke

26 October 2012

Update of DNV-OS-F101

Presentation to DNV Pipeline Committee

©Det Norske Veritas AS. All rights reserved.


26 October 201229 November 2012

DNV Pipeline Codes / Offshore Standard DNV-OS-F101

GLOBAL PIPELINE AWARD

2009 WINNER

DNV Rules for Submarine Pipeline Systems, 1976- The first complete pipeline code for offshore pipelines

- Based on allowable stress format.

DNV Rules for Submarine Pipeline Systems, 1981- Update of 1976 version and became a wide spread code

DNV Rules for Submarine Pipeline Systems, 1996- A completely new version, incorporating the limit state format with calibrated safetyfactors based on the SUPERB J IP work

DNV-OS-F101:2000- Converted to pure technical standard

DNV-OS-F101:2007- General Improvement

- Aligned with ISO3183 Linepipe standard

Global Pipeline Award 2009

DNV-OS-F101:2012- General Improvement

- Aligned with ISO 3183





26 October 2012

ISO 13623, ISO 3183 (draft)

ISO coating ISO 21809

Feed-back

Harmonization

Motivation for update



26 October 2012

General updates in DNV-OS-F101

Ease read of document

Review of formulations

- Unless otherwise agreed … shall …..… should….

- The following recommended values shall be used …





26 October 2012

Feed-back

1005 Comments Characterisation of comments

5

Commenting companies

AG der Dill inger Huttenwer ke

All seas

BP

Chevron

Europipe

ExxonMobil

Heerema

Heerema Marine Contractors

JDP

JFE-steel

Mærsk

Nippon Steel

Nord Stream

Reinertsen AS

Statoil

Subsea 7Tata Steel

Technip

Total

Woodside (No comments)

Print errors

PE Print Error – to be corrected

Comments on Modified text

MA Modified text, Agree – to be implemented

MP Modified text, Partly agree – Text to be modified

MN Modfied text, Not agree- No change in text

Comments to Original text, as per 2007

OA Original text, Agree – to be implemented

OP Original text, Partly agree – Text to be modified

ON Original text, Not agree- No change in text



26 October 2012

0

5

10

15

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25

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1 2 3 4 5 6 7 8 9 10 11 12

Characterisation of received comments

MA

MP

MN

OA

OP

ON

PE





26 October 2012

0

10

20

30

40

50

60

70

A B C D E

Characterisation of received comments



26 October 2012

1 General

Other references

Normative references are typically referred to as ‘testing shall be performed in accordance with

ISO xxx’

Informative references are typically referred to as

‘Testing may be performed in accordance with ISO xxx or ISO

‘Recommended Practice on free-span assessment is given in DNV-RP-F105‘

Complies with





26 October 2012

Comments from hearing – Comment by comment

Comment #138

Hearing version:

- In-line assemblies: Components such as tee’s, y’s, PLEM or PLET which are integrated partof the pipeline.

Comment from hearing proposed following change:

- In-line assemblies: Components such as tee’s, y’s, PLEM or PLET, spools which are

integrated part of the pipeline.

Should be straight forward to include comment…and start looking at next comment?

Sec. 8 Construction – Components and assemblies- Are in-line assemblies covered in this section? Assemblies = in-line assemblies?

9



26 October 2012


Proposed text sent sent to parties commenting on subject in the hearing for review:

- Assemblies, in-line: Components such as valves, flanges, tee’s, wye’s, PLEM, or PLETwhich are integrated part of the pipeline and installed welded to the pipeline.

- Assemblies, pipeline: Risers, pipe strings (for reeling or towing), spools which are weldedonshore.

First party proposed the following modifications:- Assemblies, in-line: Pipeline components such as valves, flanges, tee’s, wye’s, PLEM, or

PLET which are integrated part of the pipeline and connected to the pipeline during pipelineinstallation.

Second party proposed further that collars, reducers, transition pieces etc should beadded to in-line assemblies definition

Third party then proposed the following

- Assemblies, in-line: Assemblies of linepipe sections and pipeline components (see Table 1-1and Sec.1 C288) which are integrated part of the pipeline, and installed simultaneously withthe pipeline during pipeline installation.

- Sec.1 C288: Pipeline Components: Any items which are integral parts of the pipeline systemsuch as flanges, tees, bends, reducers and valves.

10





26 October 2012


Comment #138

Hearing version:

- In-line assemblies: Components such as tee’s, y’s, PLEM or PLET which are integrated partof the pipeline.

Comment from hearing proposed following change:

- In-line assemblies: Components such as tee’s, y’s, PLEM or PLET, spools which are

integrated part of the pipeline.

Final

- Assemblies, in-line: Pipeline components (see Table 1-1 and Sec.1 C291), buckle and

fracture arrestors, PLEMs and PLETs which are integrated part of the pipeline and

connected or welded to the pipeline during installation.

So even a little small comment appearing straight forward at first glance may involve

work

1004 comments left…

11



26 October 2012

2 Safety Philosophy

Target safety levels – new layout CO2





26 October 2012

2 Safety Philosophy

B 300 Systematic review of risks

- 301 A systematic review shall be carried out at all phases to identify and evaluate threats,the consequences of single failures and series of failures in the pipeline system, such that

necessary remedial measures can be taken. The extent of the review or analysis shall reflectthe criticality of the pipeline system, the criticality of a planned operation, and previousexperience with similar systems or operations. The uncertainty in the applied risk reviewmodel itself shall also be qualified.



26 October 2012

A 300 Systematic review – Section 10 - Offshore

10 Construction - Offshore

301 The overall requirement to systematic reviewin Sec.2 shall be reflected in the offshoreconstruction of the pipeline.

302 Systematic analyses of equipment andoffshore construction shall be performed inorder to identify possible critical items or

activities which could cause or aggravate ahazardous condition, and to ensure thateffective remedial measures are taken.

303 The extent of systematic review shall dependon criticality of operations and experience fromprevious similar operations.

304 The systematic analyses should be carried outas a failure mode effect analysis (FMEA) forequipment and hazard and operability studies(HAZOP) for critical operations. Recommendedpractice for FMEA and HAZOP is given in DNV-RP-H101. For HAZOP, reference is also madeto API RP 17N.

Guidance note:

- Typical items to be covered for HAZOP include:

- simultaneous operations

- lifting operations including pipe jointtransportation and storage

- dry and wet buckles including flooding of pipe

- initiation and lay down including shore pull- operations inside safety zones

- critical operations (laying in short radii curves,areas with steep slopes etc.)

- failure of equipment and measuring andmonitoring devices

- tie-in operation

- pre-commissioning activities

- environmental conditions and weather criteria

- emergency abandonment

- loss of station keeping capabilities

- survey.

- It is desired to mitigate potential hazards byengineering measures.





26 October 2012

3 Concept and Design Premise Development

Re-structured, chronologically B. Concept Development

- B 100 Concept development

C. Design Premise- C 100 Hydraulic analyses and flow

assurance

- C 200 Environmental condition

- C 300 Collection of environmental data

- C 400 Environmental data

- C 500 Pipeline route

- C 600 Route survey

- C 700 Seabed properties

D. System Design Principles

- D 100 System integrity

- D 200 Pipeline control and safety system

- D 300 External corrosion control

- D 400 Internal construction conditions

- D 500 Internal corrosion control



26 October 2012


Pressures – Incidental pressure

The incidental pressure is defined as having a probability less than 10-2 of beingexceeded during a year

If the pressure probability density function does not have a monotonic decay beyond10-2 the pressure exceeding the incidental pressure shall be checked as accidentalloads in compliance with Sec.5 D1000

The submarine pipeline system shall have a specified incidental pressure or be splitinto different sections with different specified incidental pressures. These should all

be defined at a defined reference elevation

Slide 22





26 October 2012


Pressure – Design pressure

To fulfil the requirements to incidental pressure a Pipeline Control and SafetySystem may be required.

This comprises the- Pipeline Control System (PCS) and

- Pipeline Safety System (PSS).

Slide 23



26 October 2012


Pipeline Control System (PCS)

The purpose of the Pipeline Control System is to maintain the operating parameterswithin operating envelope during normal operation

- E.g. to ensure that the local design pressure is not exceeded at any point in the submarinepipeline system

The Pipeline Control Systemshould operate automatically.

Due account shall be given to the tolerances of the pipeline control system and itsassociated instrumentation

The Pipeline Control System is a basic process control system as defined by IEC61511

Slide 24





26 October 2012


Pipeline Safety System (PSS)

The purpose of the Pipeline Safety System is to protect the submarine pipelinesystem by limiting the operating parameters within the parameter safety envelopeduring incidental operation

- E.g. to ensure that the local incidental pressure is not exceeded at any point in the pipelinesystem in the event of failure of the pipeline control system.

The Pipeline Safety Systemshall operate automatically.

Due account shall be given to the tolerances of the pipeline safety system

The Pipeline Safety shall comply with the requirements of IEC 61511.

Pipeline Safety Systems required with a probability of failure on demand of less than10-3 shall consist of two independent systems.

Slide 25



26 October 2012

4 Design – Load

Minor changes on expressions





26 October 2012

5 Design – Limit State Criteria

Scenarios and failure modes

Ultimate limit states Serviceability l. s. Control

Fracture Instability

Scenario

B u r s t i n g

F a t i g u e

F r a c t u r e

C o l l a p s e

P r o p a g a t i n g

b u c k l i n g

C o m b i n e d

l o a d i n g

D e n t

O v a l i s a t i o n

R a t c h e t i n g

D i s p l a c e m e

n t

Wall thickness des. X X X Thickness

Installation X X (X) (X) X (X) X X Lay parameters

Riser X X X X X X X X

Free-span (X) X X X Intervention

Trawling/3rd party (X) X X X Trenching/free

span/coating

On bottom stability (X) (X) (X) (X) (X) (X) X1 Trenching/Coating

Pipeline Walking X X Anchor

Global Buckling (X) X X X X Sleepers/spotrock



26 October 2012


Pressure test philosophy and criteria

The pressure containment capacity of the pipeline system is ensured by:

- Design criteria and safety factors

- Pressure testing all pressure containing parts by

- Strength pressure test; Mill pressure test for pipe joints and hydrostatic test for components (Sec.8G100), and

- Gross error leak test; System pressure test and hydrostatic test for pipeline assemblies

Unless waived by B204 or Sec.7 E107.

- Section 5 B201

Components specification

- A specification reflecting the results of the materials selection according to thissection and the pressure test philosophy in Sec.5 B200 and referring to Sec.8,shall be prepared by the Purchaser

- Section 6 C301





26 October 2012


Pressure Containment

Slide 30

¸¸

¹

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¨¨

©

§

dU mpt

he

spt

lt

SC m

beli

p p

pt p Min p p

D D D J J

;;1

Pressure ratios



26 October 2012


Linear cumulative damage

Where:

Dfat = Miner's sum

k = number of stress blocks

ni = number of stress cycles in stress block i

Ni = number of cycles to failure at constant stress range of magnitude ( ır)i orstrain range ( İr)i.

DFF = Design Fatigue Factor, see Table 5-11

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26 October 2012

Section 6 – Design-Materials Engineering

In general, the update includes:

- Rephrasing and clarifications to make requirements more clear

- The informative subsections have been updated to only include informative information

- Some of the welding requirements have been moved to Appendix C (e.g. requirements towelding consumables)

Changes (highlights):

- Removed acceptance of use of B7 bolts.

- Limits to SMYS for UNS N06625 bolting material in solution annealed condition removed.Hardness requirements still apply.

- Reference to and requirements in ISO 21809 is included for coating. Some additionalrequirements according to DNV-RP-F102 and –F106 applies.

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26 October 2012

Section 7 – Construction-Linepipe


- Rephrasing and clarifications to make requirements more clear, e.g. for dimensionalmeasurements and tolerances

Changes (highlights) to MPS/MPQT:

- Each MPQT shall include one pipe from two different test units of different heats

- For C-Mn steels with SMYS > 450 MPa, the qualification of the MPS should be completedprior to start of production

- Included essential variables to the longitudinal weld seam with regard to MPS (changes towelding wire type/thickness/configuration, flux, shielding gas, welding equipment). In caseissues only related to the welding process have been changed, the re-qualification of theMPS may be limited to the weld only (e.g. not base material testing).

- In case issues only related to the welding process have been changed, the re-qualification of the MPS may be limited to the weld only (e.g. not base material testing).

- In the specific case of failed fusion line CVN tests, retesting of further 2 sets removed fromthe failed MPQ pipe (at the same position relative to the wall thickness) is permitted prior todeclaring the MPQT as having failed.

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26 October 2012

Section 7 – Construction-Linepipe


- Reference to ISO 3183 for repair welding deleted and replaced with general and more clearrequirements.

- The proposed stricter requirements to CVN values for BM in the hearing document isdeleted. Remains similar to 2007-edition.

- CVN test temperature for duplex and martensitic stainless steels changed to be similar as forCMn-steels (less strict).

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26 October 2012

Sect. 8 – Construction-Components and Pipeline Assemblies


- Rephrasing and clarifications to make requirements more clear, e.g. acceptance criteria totesting requirements

- Update to reflect new revision of ISO 15590-1 (bends)

- Requirements to bolting materials included in Section 8

Changes (highlights):- Maximum hot forming temperature increased to 1100°C with opening to increase to 1150°C

if microalloying elements to prevent grain growth are added.

- Pressure testing with covered welds accepted. Modified requirements to pressure testingwith and without coating, e.g. hold time when acceptance is based on pressure observation.

- Sub.sec. F partly re-written and re-structured, e.g. requirements to storage andtransportation added

An invitation to a J IP with focus on Section 8 is under development. Some of thecomments to Section 8 will be handled during this J IP, e.g. a possible re-

construction of the subsections and major changes to materials and testing.

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26 October 2012

9 Construction - Corrosion Protection and WC

For

- 3-layer polyolefin coatings (3-layerpolyethylene/polypropylene),

- single layer fusion bonded- epoxy coatings and field joint coatings

ISO 21809 (part 1-3) shall apply withadditional requirements

- Recommended practice for application of linepipe coatings and field joint coating aregiven in F106 and DNV-RP-F102,respectively

For Concrete weight coatingrequirements in ISO 21809-5 shallapply with the additional and modified

requirements

For Galvanic Anodes ISO 15589-2 shallapply



26 October 2012

Section 10 Construction – Offshore

Section completely revised on hearing version compared to 2007

Highlighted that production testing is also relevant for pipe strings for reeling.Production testing requirement moved to App. C (applicable to both Sec. 10 andSec. 8).

Various comments (as normally) to buckle detection requirement. Requirement toHAZOPD/HAZID which should found basis for buckle detection. Requirement tobuckle detection changed from ‘shall’ to ‘should’.

Requirement to sorting of pipes in the pipe string removed. GN included in Sec.5that if assumed by design.

Several comments to related to change from 95% to 97% ID for gauge plates.Changed back to 95% as in 2007-version.

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26 October 2012

Appendix A Structural Integrity of Girth Welds

Reference stress shall be calculated in accordance with the plate solution specifiedin BS 7910 (not the Kastner solution)

- This will increase the crack driving force for surface flaws (more critical)

- More correct based on comparison with 3D FE fracture mechanics analyses

Plastic collapse limit (Lr cut-off)c hanged, true UTS divided by true YS for strain-based loading

- The Lr cut-off will increase, failure point will not be plastic collapse, but tearing instability orfracture toughness controlled

- Weld residual stress may be somewhat more relaxed

- For high strain situations, this will typically give larger allowable flaw sizes

How to define “upper-bound” and “lower-bound” stress-strain curves clarified (basedon statistics and amount of testing)

How to define weld over-match clarified (based on statistics and amount of testing)

Not necessary to combine installation load with all possible fatigue and operationalload cases (less conservative). Simple probabilistic-based rules introduced

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26 October 2012

Appendix A Structural Integrity of Girth Welds

New Subsection giving some guidance on FE fracture mechanics analyses

Subsection C deleted “Generic ECA for strain below 0.4%” (replaced by new AUTworkmanship criteria in Appendix D)

No safety factor on fatigue life required for fatigue crack growth analyses

Number of comments received: approx. 100 (several are the same)

- Accepted/implemented: 6

- Partially accepted/implemented:41

- Not accepted/no changes:32*

- Printing errors (implemented/corrected): 18

*Quite many comments are not directly a proposal for change, butclarification/question to Appendix A. Hence, these are in general not implemented butsome more clarifications are added.

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26 October 2012

Appendix B – Mechanical Testing and Corrosion Testing


- Moderate update to reflect gained experience, however, very few changes


- Requirement to machining of both sides for reduced thickness DWTT samples deleted.

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26 October 2012

Appendix C – Welding


- Rephrasing and clarifications to make requirements more clear, e.g. for dimensionalmeasurements and tolerances

Changes (highlights) to Welder Qualification and Welding Consumables:

- Repair welders will be qualified for all types of repair after successfully being tested on fullpenetration repair providing the welding processes are the same for the particular section

- For weld filler metal the following has been included (requirements to the weld metal strengthwas contradictory and not clear in 2007-edition):

- For welds exposed to strainİl, nom 0.4%: the weld metal yield strength measured during weldingqualification shall not be more than 20 MPa below the specified maximum yield strength of the basematerial

- For welds exposed to strainİl, nom <0.4%: the yield stress (Rt0.5) of the weld metal should be minimum80 MPa above SMYS of the base material

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26 October 2012


Changes (highlights) to Welding Procedures:

- The maximum heat input variation for a pWPS is increased from 30% to 40% and must bebased on two qualified procedures with a 20% difference in heat input allowing a ±10%

tolerance for each procedure.- The change of steel supplier is not an essential variable for components.

- More clarifications with regards to how to carry out qualification welding is given, e.g. how torecord heat input

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26 October 2012


Changes (highlights) to Examination and Testing for WPQ:

- Delayed NDT of test pieces reduced from 48 hours to 24 hours

- For longitudinal and girth welds exposed to strain İl, nom 0.4%, the fracture shall not belocated in the weld metal, while for longitudinal and girth welds exposed to strainİl, nom < 0.4%, the fracture should not be located in the weld metal.

Changes (highlights) to Material and Process Specific Requirements:

- Maximum interpass temperature for welding on CRA’s is increased from 100°C to 150°C

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26 October 2012

Appendix D - NDT

Main issues commented on and adjustments due to external hearing:

- The updated requirements of minimum 1000 lx viewing conditions for visual and liquidpenetrant inspections will be kept. DNV-OS-F101 will then comply with all standards

regarding viewing conditions.- The proposed Table D7, acceptance criteria for AUT, has been rewritten to improve clarity

and moved to Appendix E.

- H410: The paragraph has been rewritten due to comments on the new requirement of detection of a reference indicator on pipe ends by all probes. The revised text specifiesreflector and opens up for agreement on alternative reflectors if the specified reflector isfound unsuitable.

- A500/A504: Change in this paragraph was interpreted as it will become unacceptable to uselevel 1 operators. The paragraph will be rewritten to better specify the intention, that criticaltasks for the inspection as calibration, data acquisition and interpretation of the results shallinclude personnel qualified to at least level 2.

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26 October 2012

Appendix E - AUT

Main issues commented on and adjustments due to external hearing:

- The scope of a full qualification will remain as according to DNV-RP-F118.

- Added clear guideline on AUT validation in a new subsection, as requested by severalcompanies. AUT validation requirements will be based on DNV-RP-F118, with opening for alimited scope (min. 12 defects) for applications involving <0.4% accumulated strain.

- Subsection E: Workmanship style acceptance criteria for AUT, applicable when the

accumulated strain is <0.4%, is added. This table has been moved from Appendix D, andwas commented on by several companies.

- B502: The requirement of having a weld in the calibration block for inspection of CRAmaterials has been abandoned.

- B413: A wider range of over trace in adjacent fill channels will be allowed, in order to betterreflect the actual inspection situation. The range has been adjusted from between 6 dB -10dB to between 5%-40% FSH when reference is set at 80% FSH.

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26 October 2012

Safeguarding life, property

and the environment

www.dnv.com

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