1 GENERAL

1.1 Introduction
Abu Dhabi Company for Onshore Oil Operations (ADCO) intends to increase crude oil
production from current production rate of 1.4 million barrels of oil per day (MMBOPD) to 1.8
MMBOPD.

To accomplish this, ADCO plans to develop the new reservoir Habshan-1 at Bab to produce
at a sustainable rate of 30 MBOPD which is part of the Bab field expansion along with other
ongoing developments to sustain additional production of 420 MBOPD.

The Bab field is located in a desert area approximately 160 km southwest of Abu Dhabi city.
The field covers an area of approximately 45 km by 25 km. The main processing facilities are
located around Habshan. The field is sour, with wells to the northeast exhibiting generally
higher H2S content than wells to the southwest.

As part of the ongoing Bab Thamama-G and Habshan-2 1.8 MMBOPD Development project,
the existing Bab facilities at BCDS will be de-bottlenecked by Q3, 2012 and 4 new RDSs
(RDS-7, 8, 9 and 10) will be installed. The de-bottlenecked BCDS facilities will continue to
process production from Bab Thamama-B, Thamama-G and Habshan-2 zones in addition to
the production from Habshan-1 brought online by this Project.

Thamama-B, Thamama-G, Habshan-2 and new Habshan-1 reservoirs are located in the
existing ADCO BAB field.

The project objective for phase-2 is to carry out Engineering, Procurement & Construction
(EPC) & (EP) of additional twelve (12) oil producer wells along with twelve (12) water
injectors connected to the Identified existing REMOTE DEGASSING STATION (RDS) and
tie-in to existing WATER INJECTION CLUSTERS (WICs’) header respectively to optimize
and maintain the desired productivity levels at the BAB CENTRAL DEGASSING STATION
(BCDS) and additionally achieve future production targets & Bab Habshan-1 (HB-1) Full Field
Development (FFD).

Engineering, Procurement and Construction (EPC) of eight (8) nos. oil producer wells and
their associated flow lines which shall be connected to existing RDS. The fluid from each of
these eight (8) oil producer wells will be transported to already existing gathering manifolds in
RDS-9 via six (6) inch flow lines.

Engineering and Procurement (EP) of the four (4) nos. oil producer wells and their associated
flow lines which shall be connected to existing RDS. The fluid from each of the four (4) oil
producer wells will be transported to already existing gathering manifolds via six (6) inch flow
lines, in RDS-7, RDS-8, RDS-9 and RDS-10.

Engineering, Procurement and Construction (EPC) scope for WI system consist of seven (7)
nos. water injection wells and their associated flow lines. The injection water from the
associated existing WIC shall be supplied to each of the seven (7) water injection wells via
flow lines of appropriate sizes, connected to the water injection header.

Engineering and Procurement (EP) of five (5) nos. water injection wells and their associated
flow lines which shall be connected to existing water injection cluster header.

2 SCOPE OF THE DOCUMENT

 The scope of this document is to carry out the stress analysis of 6” Oil Flow line from Bb- 936
to RDS-9.
The pipeline stress analysis is carried out to study the behavior of the pipeline at critical
locations such as above ground section, transition zone, buried section, Rig / road crossing
and bend angles at IP points etc.
The on-plot piping has been modeled up to the nearest anchor location; further these lines
will be part of separate system. The pipeline is modeled as per actual profile shown in
pipeline alignment sheets. The pipeline alignment is rotated in line with on plot piping plant
north.
This calculation or stress analysis is carried out using CAESAR-II Version 7.0. The stress
analysis is carried out for design pressure/ temperature, operating temperature condition as
well as for hydro test condition & minimum design temperature.
The stress analysis is carried out in accordance with ASME B31.8 & Specification for Pipeline
Flexibility Analysis (Doc. no. 11.78.12.1616) and other project specifications as listed in
section 4.0 of this document.

3 INPUT PARAMETERS

The following input parameters used in the Stress Analysis are in accordance with,
Specification for Pipeline Flexibility Analysis (Doc. no. 11.78.12.1616) and other applicable
project documents as listed in section 4.0 above.

Pipeline Parameters
Piping Class 251140-R
Material CS API 5L X 52, PSL-2
Pipe Size 6”
Wall Thickness 14.27 & 12.7 mm
Corrosion Allowance 3.0 mm
Process Contents Process Oil
Fluid Density 595 Kg/m3
Design Pressure 275.8 Barg
Operating Temperature 71.6 to 58ºC (Note-2)
Maximum Design Temperature 85 ºC (Solar black bulb temperature)
Minimum Design Temperature -15 ºC
Installation Temperature 21 ºC
 Testing Medium Water
Leak Test Pressure 345 Barg
Hydro Static Strength Test Pressure (Barg) 505 Barg
Friction coefficient (steel to Steel) 0.3
Friction Coefficient (Steel to Soil) 0.4
Thickness tolerance +10%, - 5%
Soil Parameters
The minimum buried depth to the top of pipe Surface laid (Note 1)
Angle of internal friction 30 degree
Compacted soil density 1550 Kg/m3

Notes:
1. However, at rig/ asphalt/ road crossings/ UG pipeline crossings the pipeline is buried and
burial depth followed as per alignment sheet.
2. The max operating temperature for pipe line portion is considered as per process
simulation study report of OPW temperature profiles (Refer attachment-14).

3.1 Bend Radius

Cold Bend (field fabricated used along the pipeline) = 40D & 60D

3.2 Soil Modelling

For underground pipeline portions as well as for surface laid portions, CAESAR II
underground pipe modular is applied as per CAESAR II Basic Model.
In case of surface laid pipeline, the soil stiffness has been calculated at the depth of 84.15
mm (Half diameter of 6” pipeline) as detailed in below table. The friction factor between pipe
and soil is considered as 0.4.

Vertical down Stiffness (KN/mm/(m of

Depth of cover
pipeline length))

84.15 mm 3.9

Stiffness values are calculated by CAESAR II Basic Model. The soil properties for
calculations taken from Geotechnical Investigation Report 11-78-23-1627.

4 STRESS ANALYSIS MODELS

Figure shown below is the CAESAR-II generated overall isometric view of 6” Oil Flow line
from Bb 936 to RDS-9.
5 ASSUMPTIONS AND CONSIDERATIONS

 7000 Number of thermal cycles is assumed for 30 Years design life of the pipe work.
 This assumption is based on ASME B 31.3 and normal engineering practice for stress
analysis for said design life.

6 CONCLUSION
1

 The stresses at all cases (i.e. operating, sustained, expansion and Hydro test are within
 code allowable limit. Thermal displacements at critical locations are acceptable. The
above ground restraint loads are acceptable for design.
 Either 40D or 60D bends are used in all IP’s and vertical bend areas.

 The calculated loads on supports are acceptable for support design.

 The static analysis result revealed that the proposed pipeline routing is safe and
acceptable.
 The maximum lateral displacement is restricted below 500600mm in operating condition
case..
 25 Nos of expansion loops have been added to the system to control the displacement &
stresses and the same have been marked in in relevant alignment sheet (Dwg. No.
11.78.22.2042 Sht. 1 of 13 to 13 of 13)