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Expansionloopenclosureresolvessubsealine
problems
08/03/1998
SharonK.Rich,AlvinG.Alleyne
IntecEngineeringInc.
Houston

Theenclosedexpansionloopliesondeckinpreparationforinstallation(Fig.1).

The"dogoff"clamp(left)hasbeeninstalledontheflowline(Fig.2,[14,229bytes]).
Thebearclamp,forpipelineexpansionloopalignmentawaitsinstallation(Fig.3[10,568bytes]).
Theenclosedexpansionloopisbeingloadedoutforinstallation(Fig.4[15,105bytes]).
RecentdesignandconstructionofaGulfofMexicosubseapipelineillustratetheuseofburied,enclosedexpansionloopstoresolve
problemsfromexpansionandupheavalbuckling.
Buried,subseapipelinesoperatingathightemperaturesandpressuresexperienceextremecompressiveloadscausedbytheaxial
restraintofthesoil.Thehighaxialforcescombinedwithimperfectionsintheseabedmayoverstressthepipelineorresultinupheaval
buckling.

Typically,expansionloops,or"doglegs,"areinstalledtoprotectthepipelinerisersfromexpansionandtoalleviateaxialforces.
Buriedexpansionloops,however,arerenderedvirtuallyineffectivebythelateralrestraintofthesoil.Alternativemethodstoreduce
expansionmayincreasethepotentialofupheavalbucklingoroverstressingthepipeline.
Therefore,systemdesignmustconsiderexpansionandupheavalbucklingtogether.Discussedherearemethodsofpreventionand
controlofexpansionandupheavalbuckling,evaluatingtheimpactontheoverallsystem.
Expansion,bucklingforces

Apipelinewillexpandorcontractwhentemperatureandpressurevaryfrominstallationconditions.Conditionsduringconstruction,
therefore,becomethereferencetemperatureandpressure.Forpresentpurposes,discussionwillbelimitedtoexpansion,butsimilar
issuesmayrequireaddressingforcontraction.
Asthepipelineexpands,itwillfollowthepathofleastresistance,whichleadsdirectlytotheriserstotheplatform.
Ifthelowerriserspanisinsufficientlyflexibletoabsorbexpansionwithinthepermissiblestresslimit,expansionloopsaretypically
placedjustbeforeeachriser.Whentheloopsdonotfunctionproperly,aswhenburied,theyoverstressatthefirstbendexperiencing
thepipelineexpansion.
Theseveralmethodsreadilyavailabletoreducetheexpansioninthepipelineresultinbuildupofaxialforcesinthepipelineandlead
toupheavalbuckling,amodeoffailureintrenchedandburiedpipelines.Pipelinesrestingontheseabedmayalsobucklebuttendto
bucklelaterallywherethereisinsignificantresistance.
Upheavalbucklingresultsfromtheaxialforcegeneratedfromtheexpandingpipelinecombinedwithanuneventrenchbottomwhich
resultsfromthetrenchingprocess,undulationsintheseabed,arockformation,oranareaofdensersoil.Trenchunevennessis
generallyreferredtoasan"imperfection."
Axialforceandimperfectionarerelated.Ingeneralterms,themoreuneventhetrenchprofile,thelowertheaxialforcerequiredto
produceanupheavalbuckle.
Methodstocontrolexpansionandupheavalbuckling,discussedpresently,wereinvestigatedforthedesignofahighpressureand
temperature,buriedsourgasflowlineoffshoreinMobileBay,Ala.,foramajoroperator.
Controllingexpansion

Thereareseveralconventionalmethodsusedtohandleexpansionwhich,alongwithsomeunconventionalmethods,were
investigatedandincludethefollowing:

Anchorflangesandconcreteand/orroughfusionbondedepoxy(FBE)coatingseachperformsthesamefunctionofincreasing
thefriction,thusreducingoreliminatingexpansioninthepipeline.Thisincreaseinfriction,however,resultsinthebuildupof
axialforcesinthepipelinecontributingtoincreasedriskofupheavalbuckling.
Coldspringingtheriserhasprovensuccessfulformanypipelines.Coldspringingprestressestheriserduringconstruction,
resultinginsplittingthedifferencebetweentheprestressandtheexpansionloadstobeencounteredduringoperation.This
allowstherisertoaccommodatelargeramountsofexpansion.Coldspringingallowsforthenaturalreliefofthepipeline
stressesthroughtheriser.Evenallowingforcoldspringing,themiddleofthepipelinemaybeanchoredbecauseoffrictionand
experiencethemaximumaxialforcepossiblyresultinginupheavalbuckling.
Theriserbendmaybereinforcedwithabrace,distributingtheforcesovermoreoftheriser.Reinforcingislimitedintheamount
ofexpansionitmayaccommodate,however,anddoesnotalleviatetheforcesinthemiddleofthepipeline.
Pipeinpipeconstructionisanoptionthathasbeenutilizedwhenothersolutionsfail.Itiscostlybecausetheproductcarrier
pipeisinsideajacketpipenormallytwosizeslarger.Thetwopipesaremechanicallyconnectedwithbulkheadsthattransfer
theloadsfromthecarrierpipetothejacketpipe.
Whilethecarrierpipeexpands,thejacketpiperesiststheexpansionloads.Thespacingandsizeofthebulkheadsare

determinedtoeliminatebucklingofthecarrierpipewithinthejacketpipetominimizeinstallationexpense.
Thestructuraldesignofthepipeinpipevirtuallyeliminatesexpansionandthepotentialofupheavalbucklingifthesystemis
properlydesigned.Thecostofextramaterials,however,andthelengthyprocessoffabricatingthepipeinpipewarrant
investigationofotheroptions.
Expansionloopsanddoglegsservethepurposeofactingasaspringtoaccommodateexpansionattherisers.Several
expansionloopanddoglegconfigurationswereinvestigatedfortheinstallationinMobileBay,includingconventionalUloopsof
variousdimensions,andvariousanglesforthedoglegs.
Itwasfoundthatburiedexpansionloopsanddoglegsexperiencehighlateralresistancethatinturncreateslocalizedhigh
stressesatthefirstbend.Onlyashortlengthoftheexpansionloopwasburied,withminimaleffectiveness.
Toillustratetherelativeeffectiveness,itwasfoundthataconventionalexpansionloop40x40ftwaseffectiveonlyover4ft
whenburiedandhadamuchreducedcapacityforexpansion.Similartoothermethods,theexpansionloopplacedattheriser
wouldnotrelievethestressesinthemiddleofthepipeline.
Azigzagshapedpipelinehasbeenemployedtoaccommodateexpansionandrelieveaxialforcesthroughoutthepipeline.1
Thepipejointswerebentinazigzagconfigurationanddoublejointedforinstallation.Eachjointaccommodatedsomeofthe
expansionandrelievedsomeoftheaxialforce.
Althoughthissolutionhasapplications,theadditionalcostandconcernsoffabricationandinstallationlimititsapplicability.
Snakingthepipelineduringinstallationappearedpromisinginprincipal.Thepipelinewouldactasitsownspringthroughoutthe
length,accommodatingtheexpansionandalleviatingtheaxialforces.
Severalconfigurationsthatwereconsideredeasilylayablewereinvestigatedforarangeofsoilconditions.Itwasdeterminedthatthe
pipelinefollowsthepathofleastresistance,whichisaxially.
Snakingthepipelinerequiresadditionalpipewhichcontributestomorecostsandmoreexpansionattheends.
Controllingupheavalbuckling

Upheavalbucklingmaybecontrolledoreliminatedwithrockdumporadditionalburial.Eachmethodappliesadditionalweightonthe
pipeline,preventingupwardmovement.
Therockdumpmaybeappliedwhereneeded,usuallyafterabucklehasoccurred,orovertheentirepipeline.Theadditionalweight
onthepipelinealsoreducesexpansionoverthelengthofthepipeline,thusreducingstressattherisers.
Thissimplesolutionis,however,costlyanddoesnotaddresstheentireproblem.
Whilethepipelinemaybeheldbelowtheseabedbytheweightonit,itmaybeoverstressed.Mostcodesallowthepipelineto
experiencepredictableandcontrollableoverstresswithinastrainlimitation.
Althoughthisoptionshouldbetakenadvantageof,itstillmaynotbeenoughforallcases.Smalldiameterpipelinesareparticularly
susceptibletoupheavalbucklingandoverstressingandrequireadditionalconsideration.
Designprocess

Investigationoftheseoptionsdeterminedthatexpansionloopsoverthelengthofthepipelinemustbeemployedtoprotecttherisers
andreducetheaxialforcewithinthemiddleofthepipeline.Thisconclusionledtotwooptions:usingmanysmallburiedloopsor
findingawaytohaveseverallargerloopsworkasiftheywerenotburied.
Becauseitwasimpracticaltoinstallmanysmallloops,methodsofpreventingsoilfromaccumulatingaroundtheexpansionloop
whenburiedwasinvestigated.
Researchofmethodstoisolatetheloopsfromthesoildeterminedthatthemostlikelycommerciallyavailableoptioncalledfor

concrete"doghouses."Theseareusedtoprotectpipelinesandexpansionloopsfromdroppedobjects.
Buttherewasnoexistingconfigurationofthedoghousessuitableforburial.Andfabricationofcustomconcretehousingswas
expensiveandheavyforconstruction.Therefore,itwasconcludedthatfabricationofasteelenclosurewasthemostlikelysolution.
Withadirectionforthesystemdesignidentified,theexpansionloopdesignwasoptimized.Becauseoftheweightofthesteel
enclosureaddedtotheexpansionloop,itwasdesirabletominimizethesizeandquantityoftheexpansionloops.
ExpansionloopshapesinvestigatedincludedU,omega,helix,anddoublehelix.Afiniteelementanalysis(FEA)modelwas
developedforeachshape.
Thehelixwasfoundthemostefficientbyfar.Thedoublehelixwouldprovideadditionalbenefitbutalmostdoubledthematerialcosts
andweight.Theresultingenclosurewouldalsohaveprotrudedfromthenaturalseabedorrequiredadditionalburial.
Theinitialsize,quantity,andplacementoftheexpansionloopsweredeterminedwithamathematicalmodelbasedoninternaldesign
guidelinesusingtheultimatesoilfriction2forburiedpipelines.Fromthemathematicalmodel,theanchorlocationsandexpansion
couldbedetermined,resultingintheplacementandsizingoftheexpansionloops.
Theoptimumspacingwouldprotecttherisersfromoverstressingandminimizetheaxialforceswithinthepipeline,thusreducing
potentialforupheavalbuckling.
Thelowertheaxialforcescouldbemade,thelargertheimperfectionheightsthatcouldbeallowedduringconstruction.Theaxial
forcesmustbereducedtoaleveltoallowachievableimperfectionheightsduringconstruction.
Theupheavalbucklingpotentialandcorrespondingstresslevelswerecheckedthroughoutthedesignwithamathematicalmodel.3
Thisconstantverificationofthedesignaidedintheoptimizationofthesystemdesign.
FEAmodeldevelopment

AnFEAmodeldevelopedforthedesignusedindustryrecognizedsoftware.Tospeedinvestigationofmanyoptions,aprogramfor
themodelwasdevelopedwiththesystemnodalconfiguration,elementdefinition,andtemperaturegradientcalculatedina
spreadsheettobereadintotheprogram.
Thetemperaturegradientwascalculatedbasedontheresultsofthethermalhydraulicanalysis.Thisenabledeachnodetohavea
uniquetemperature,reducingpotentiallyunnecessaryconservatism.Mostoftheinputvalueswerecalculatedintheprogramto
minimizeinputchangesfromcasetocase,thusreducingentryandcheckingtime,andpotentialforerror.
Thesoilwasmodeledindetail.Thesoilwasrepresentedaxiallyandlaterallyalongthelengthofthepipeline.
Nonlinearspringswereusedtorepresentthesoil'sresistancetomovement.Thelateralresistancefortheriserbendswasmodeled
separatelyateachnodetoallowforthesoil'spressurevariancewithburialdepth.
TheresultsoftheFEAmodelprovedthemathematicalmodelaccurate.Theinitialplacementandsizeoftheexpansionloopsproved
tobealmostperfectlyoptimizedonthefirstconfigurationoftheFEAmodel.Themathematicalmodelprovedtobeslightly
conservativeandthusausefulpreliminarydesigntool.
Designoptimizationhadtoconsidervaryingsoil,startup,andoperatingconditions.Thefinalconfigurationhadtosatisfyall
conditions.ThemathematicalmodelwasusedtoreduceFEAmodelconfigurationchangestoachievefasteroptimization.
Thespacingoftheexpansionloopsconsideredthejointlengthstoallowforeaseofplacementduringinstallation:ajointspacing,for
example,similartothatspecifiedforanodes.
Whentheoptimizedconfigurationwasdeterminedfromthemathematicalmodel,thesystemwasverifiedwiththeFEAmodeltomeet
allconditions.Withtheexceptionoffurtherdesignscenarios,theconfigurationrequirednofurtherrefinementfromthatproposed
basedonthemathematicalmodel.

Temperature
considerations

Caremustbetakenwhenestablishingthecasestobeinvestigatedwithrespecttotemperature.Aspreviouslymentioned,the
temperatureatwhichthepipelinewasinstalledisthereferencetemperatureforallfurtherexpansion.Thisreferencetemperatureis
oftenconfusedwithambienttemperaturesusedforthermalhydraulicanalysis.
Thisanalysistypicallyusedthelowestambienttemperaturetobeexperiencedduringoperationastheworstcaseforhydrate
formationingaslinesandwaxbuildupinoillines.
Itisnottheworstcaseforexpansion,however.Thatcaseisthehighestflowrate,atthehighestinlettemperatureandpressure,and
atthehighestambienttemperature.Itislikelythatthereferencetemperatureforexpansionwillbedifferentfromtheambient
temperatureforthethermalhydraulicanalysis.
Thetemperatureinteractionmaybeillustratedwiththecaseofawinterorspringinstallation,establishingalowreference
temperature,thenlateroperatingthepipelineinthesummer,withahighambienttemperature.
Thisscenariorepresentstheworstcaseforexpansion.Itcanbeseenthatitmaybebeneficialtoinstallhightemperaturepipelinesin
thesummertominimizethedifferencebetweenthereferenceandoperatingtemperatures.
Enclosuredesign

Withthesizerequirementsfortheexpansionloopsestablished,onlydesignoftheenclosureremained.Throughoutthesystem
optimizationprocess,theexpansionloopdesignwasconsideredbasedonweight,fabrication,groundshippinglimitations,and
installation.
Withtheseconsiderationsalreadyinvestigated,theenclosuredesignwaslefttoconsideruninhibitedexpansionloopmovement,
structuralintegrityduringhandlingandinstallation,easeoffabrication,liftingmethods,andeaseofburial.
Fromtheseconsiderations,thedesignwasdevelopedwiththeuseofindustryrecognizedstructuralsoftware.
Themajorconcernsinthestructuraldesignoftheenclosurewere:

Todesigntheshellplatingtoresistthesoilpressureloadsintheburiedcondition
Toensuretheshellwasadequatefordifferentialhydrostaticpressureduringthefloodingoperation,forretrievalattheendof
life,orunplannedretrievalduringtheinstallationoperation
Toavoidhighshockloadsintheliftslings.
Theparticularconcernwithshockloadingwasaresultoftherelativelylargemassofenclosedwaterandhydrodynamicaddedmass
incomparisontothelowsubmergedweight,especiallybeforeinstallationfloodingwascomplete.
Ifupwardhydrodynamicaccelerationresultedinforcesgreaterthanthesubmergedweight,theslingswouldgoslackandthe
structurewouldfreefallduringthedownwardacceleration.
Themaindesignfeaturesoftheenclosureincludethefollowing:

Teflonpaddedsupportsaboveandbelowtheexpansionlooptoprovideforfreemovement
Moneloverlayontheexpansionloopattheentranceandexitoftheenclosureforabrasionresistance
Bafflestominimizesoilthatenterstheenclosurefromaccumulatingneartheexpansionloop
Stiffenerstoreduceplatethickness
Largeandnumerousventswithcapsforrapidflooding
Opencentertominimizeweightandaidinburial
Installationcollarsaroundthepipeontheinsideoftheenclosuretoresistinstallationtensionontheexpansionloop.
Fig.1showstheenclosureonthedeckoftheinstallationbarge,presentingthegeneralconfigurationoftheenclosure.
Installation

Amonginstallationoptionsconsideredwerethefollowing:

Installingtheexpansionloopinthepipestringonthebarge
Pickingupthepipelineafterinstallation,cuttingoutalengthofpipe,andinstallingtheexpansionloop
Usingaspoolpieceflangedinthepipestringduringinstallationandpickingupthepipelineafterinstallationtoreplacethespool
piecewiththeexpansionloop.
Thefirstoptionwasselected.Itwouldrequirecarefulplanningandcoordinationwithasecondvessel,butitwasseenasthemost
efficientmeansofinstallation.
Thesecondvesselwastobeajackuptoprovidestabilityfortheexpansionloopduringinterfacewiththesurf.Thelaybargewould
passtheexpansionlooptothejackupandcontinuelayingawayasthejackuplowerstheexpansionlooptotheseabed.
Thesecondoptionwasselectedasthealternatemethod.Expansionloopinstallationrequirescalmerweatherthannormallaying.
Therefore,ifweatherweredelayinginstallationbutnormallaycouldoccur,thelaybargecouldlatercomebackandinstallthe
expansionloops.
Ifthisoptionwereemployed,considerationofanygaininthepipelineduringtheliftingwouldhavetobecompensatedforbyplacing
theexpansionloopawayfromtheoriginalpositionofthepipeline.Ifslackweretakenupbytheexpansionloop,itseffectiveness
wouldbediminishedoreliminated.
Thethirdoptionwasnotconsideredviablebecauseofthehighpressure,sourgas.Potentialleakingoftheflangewasan
unacceptablerisk.Inothercases,thismaybethemostefficientmethodofinstallation.Aswiththesecondoption,gaininthepipe
mustbeconsideredandaccountedfor.
ConstructionwascarriedoutinDecember1997throughFebruary1998.Installationprocedureswerecarefullyplannedtominimize
delay.
Theprocedureforinstallingtheenclosedexpansionloopsinvolvedthefollowingsteps:

1. Usinga"dogoff"clamptosecurethepipelineandreleasethetensioners(Fig.2)
2. Cuttingthepipeandpushingthecutpipebackuptheweldingstall
3. Positioningtheenclosureinthepipestring
4. Liningupthepipelineandexpansionloopwithabearclampforwelding(Fig.3)
5. Oncethepipelineandexpansionloopweresecured,removingtheclampandfinishingtheweld
6. RepeatingSteps4and5fortheothersideoftheexpansionloop
7. Passingtheenclosurefromthebargecranetothejackupcrane
8. Pullingthebargeforwardwhileloweringtheenclosurewiththejackup(Figs.4and5).
Thisprocedurewasfollowedduringinstallationandworkedwithoutdelayorincident.
Thefinaltaskforconstruction,buryingtheenclosures,wasperformedwithhandjetting.Itwentwell,withtheexceptionofweather
downtime.
References

1. Lanan,G.A.,andBarry,D.W.,"MobileBayFairwayFieldFlowlineProject,"24thAnnualOffshoreTechnologyConference,May
1992,Houston.
2. Audibert,J.M.E.,etal.,"DesignofPipelinestoResistSeafloorInstabilitiesandhydrodynamicForces,"ASMEEnergy
TechnologyConferenceandExhibition,Houston,November1978.
3. Palmer,A.C.,etal.,"DesignofSubmarinePipelinesAgainstUpheavalBuckling,"22ndAnnualOffshoreTechnology
Conference,May1990,Houston.
TheAuthors

SharonK.RichisaprojectengineeratIntecEngineeringInc.,Houston,with6years'experienceininternationaloffshorepipeline
projectsfortheoilandgasindustry.RichholdsaBSinmarineengineeringfromTexasA&MUniversityandisamemberofthe
SocietyforNavalArchitects&MarineEngineers.

AlvinG.AlleyneisaseniorprojectmanageratIntec,currentlyonassignmenttoIntecEngineeringBV,Leiden.Hehas33years'
experienceininternationaloffshoredesignandconstruction.AlleyneholdsaBSfromtheUniversityoftheWestIndies,Trinidad,an
MBAfromtheUniversityofHouston,andisaregisteredprofessionalengineerinTexas.

Copyright1998Oil&GasJournal.AllRightsReserved.

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