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Riser Design
Riser Design
Riser Design
RISER DESIGN
DEP 31.40.10.10-Gen.
December 1999
(DEP Circular 16/02 has been incorporated)
This document is confidential. Neither the whole nor any part of this document may be disclosed to any third party without the prior written consent of Shell International
Oil Products B.V. and Shell International Exploration and Production B.V., The Hague, The Netherlands. The copyright of this document is vested in these companies.
All rights reserved. Neither the whole nor any part of this document may be reproduced, stored in any retrieval system or transmitted in any form or by any means
(electronic, mechanical, reprographic, recording or otherwise) without the prior written consent of the copyright owners.
DEP 31.40.10.10-Gen.
December 1999
Page 2
PREFACE
DEPs (Design and Engineering Practice) publications reflect the views, at the time of publication, of:
Shell Global Solutions International B.V. (Shell GSI)
and
Shell International Exploration and Production B.V. (SIEP)
and
Shell International Chemicals B.V. (SIC)
and
other Service Companies.
They are based on the experience acquired during their involvement with the design, construction, operation and
maintenance of processing units and facilities, and they are supplemented with the experience of Group Operating
companies. Where appropriate they are based on, or reference is made to, international, regional, national and industry
standards.
The objective is to set the recommended standard for good design and engineering practice applied by Group
companies operating an oil refinery, gas handling installation, chemical plant, oil and gas production facility, or any other
such facility, and thereby to achieve maximum technical and economic benefit from standardization.
The information set forth in these publications is provided to users for their consideration and decision to implement.
This is of particular importance where DEPs may not cover every requirement or diversity of condition at each locality.
The system of DEPs is expected to be sufficiently flexible to allow individual operating companies to adapt the
information set forth in DEPs to their own environment and requirements.
When Contractors or Manufacturers/Suppliers use DEPs they shall be solely responsible for the quality of work and the
attainment of the required design and engineering standards. In particular, for those requirements not specifically
covered, the Principal will expect them to follow those design and engineering practices which will achieve the same
level of integrity as reflected in the DEPs. If in doubt, the Contractor or Manufacturer/Supplier shall, without detracting
from his own responsibility, consult the Principal or its technical advisor.
The right to use DEPs is granted by Shell GSI, SIEP or SIC, in most cases under Service Agreements primarily with
companies of the Royal Dutch/Shell Group and other companies receiving technical advice and services from Shell GSI,
SIEP, SIC or another Group Service Company. Consequently, three categories of users of DEPs can be distinguished:
1) Operating companies having a Service Agreement with Shell GSI, SIEP, SIC or other Service Company. The
use of DEPs by these operating companies is subject in all respects to the terms and conditions of the relevant
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of a Service Agreement or otherwise).
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which requires that tenders for projects, materials supplied or - generally - work performed on behalf of the said
users comply with the relevant standards.
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and SIC disclaim any liability of whatsoever nature for any damage (including injury or death) suffered by any company
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any company affiliated to these companies that may issue DEPs or require the use of DEPs.
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ascertain how users implement this requirement.
All administrative queries should be directed to the DEP Administrator in Shell GSI.
DEP 31.40.10.10-Gen.
December 1999
Page 3
TABLE OF CONTENTS
1. INTRODUCTION ........................................................................................................5
1.1 SCOPE........................................................................................................................5
1.2 DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS .........5
1.3 DEFINITION................................................................................................................5
2. DESIGN INTERFACES ..............................................................................................7
2.1 GENERAL ...................................................................................................................7
2.2 TOPSIDE INTERFACE...............................................................................................7
2.3 JACKET INTERFACE.................................................................................................7
2.4 PIPELINE/EXPANSION SPOOL INTERFACE...........................................................7
3. RISER/TIE-IN CONCEPTS.........................................................................................9
3.1 SUMMARY OF MAIN RISER TYPES.........................................................................9
3.2 RISER INSTALLATION METHODS ...........................................................................9
3.3 SUBSEA TIE-IN METHODS .....................................................................................11
3.4 FLEXIBLE SPOOLS .................................................................................................12
3.5 SELECTION OF RISER/PIPELINE TIE-IN METHOD ..............................................12
3.6 AVAILABLE CONSTRUCTION METHODS .............................................................12
4. RISER ROUTING AND LOCATION.........................................................................13
4.1 BASIC ROUTING REQUIREMENTS .......................................................................13
4.2 APPROACH TO PLATFORMS.................................................................................13
4.3 SAFETY ....................................................................................................................14
5. DESIGN DATA .........................................................................................................15
5.1 RISER SYSTEM/PLATFORM DATA........................................................................15
5.2 SOIL DATA ...............................................................................................................16
5.3 METOCEAN DATA ...................................................................................................16
5.4 ATMOSPHERIC CONDITIONS ................................................................................17
5.5 EARTHQUAKE .........................................................................................................17
5.6 RETURN PERIODS..................................................................................................17
5.7 DIRECTIONALITY ....................................................................................................17
6. RISER AND TIE-IN SPOOL ANALYSIS ..................................................................18
6.1 FAILURE MODES.....................................................................................................18
6.2 DESIGN LOADS .......................................................................................................18
6.3 LOAD CASES ...........................................................................................................19
6.4 WALL THICKNESS DETERMINATION....................................................................20
6.5 PIPELINE EXPANSION............................................................................................20
6.6 EXPANSION LOOP ..................................................................................................22
6.7 RISER STRUCTURAL ANALYSIS ...........................................................................22
6.8 ALLOWABLE STRESSES ........................................................................................23
6.9 ALLOWABLE STRAINS............................................................................................23
6.10 OVALISATION ..........................................................................................................23
6.11 COLLAPSE ...............................................................................................................23
6.12 VORTEX SHEDDING ...............................................................................................23
6.13 FATIGUE...................................................................................................................24
7. RISER SUPPORT DESIGN......................................................................................25
7.1 RISER SUPPORT TYPES........................................................................................25
7.2 DESIGN CONSIDERATIONS...................................................................................25
7.3 LOADING CONDITIONS ..........................................................................................26
7.4 CORROSION PROTECTION ...................................................................................26
8. J-TUBE DESIGN ......................................................................................................27
8.1 DESIGN DATA..........................................................................................................27
8.2 J-TUBE ROUTING ....................................................................................................27
8.3 J-TUBE SIZING AND RADIUS OF CURVATURE....................................................27
8.4 PULL-IN LOADS .......................................................................................................27
8.5 STRUCTURAL DESIGN OF J-TUBE AND SUPPORTS..........................................28
DEP 31.40.10.10-Gen.
December 1999
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APPENDICES
APPENDIX 1 FIGURES .........................................................................................................41
DEP 31.40.10.10-Gen.
December 1999
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1. INTRODUCTION
1.1 SCOPE
This new DEP specifies requirements and gives recommendations for the design of
offshore pipeline riser systems, which include the piping, riser clamp supports and any
expansion spool or anchoring system at the base of the platform. This DEP identifies a
broad approach to the design including:
• definition of riser system and interfaces;
• potential riser concepts;
• riser routing;
• analysis requirements;
• support design;
• J-tube design;
• fittings and materials.
This DEP does not present a methodology, but is intended to act as a checklist of design
activities for consideration by an experienced engineer.
For the purpose of this DEP, it is assumed that the riser design is based on
DEP 31.40.00.10-Gen.
The scope of this DEP includes only rigid metallic risers; flexible risers and non-metallic
risers are excluded from the scope.
1.3 DEFINITION
1.4 ABBREVIATIONS
1.5 CROSS-REFERENCES
Where cross-references to other parts of this DEP are made, the referenced section
number is shown in brackets. Other documents referenced in this DEP are listed in (15).
DEP 31.40.10.10-Gen.
December 1999
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2. DESIGN INTERFACES
2.1 GENERAL
The riser system shall be designed as a part of the total offshore pipeline system. For
design purposes, it is necessary to define the extent of the riser assembly and to establish
the interfaces between the riser system and adjacent systems. The interfaces provide a
point where loading and/or displacement, and the requirements of the various systems can
be defined and reconciled.
The riser interface points can be summarised as follows:
• topside and supports;
• jacket and supports;
• pipeline/tie-in spool.
The riser analysis model shall take into account the effects of the interface points as further
detailed below.
of connection, geometry and type of riser and should be agreed in each case. The following
design issues shall be addressed:
• design responsibility;
• location of code breaks;
• riser routing;
• pipeline approach;
• expansion spool layout;
• overlap of riser and expansion spool structural analysis (often performed in one analysis
from pipeline to pig trap);
• the tie-in method.
DEP 31.40.10.10-Gen.
December 1999
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3. RISER/TIE-IN CONCEPTS
3.2.1 General
Risers are usually pre-installed with the jacket structure. Otherwise they can be retrofitted
onto existing platforms. This may be by the conventional method of lift, set and subsea tie-
in. Alternatively, one of the following methods may be used without the need for subsea tie-
ins:
• stalk-on method;
• bending shoe riser method;
• barefoot riser;
• J-tube installation (8).
In deeper waters, the handling of the pipe and riser becomes increasingly difficult and even
hazardous to both pipe, equipment and personnel.
The main advantages of this technique are:
• weld connections are made above surface and can be fully inspected, ensuring weld
quality;
• diver activities are relatively simple, requiring only a normally-skilled team using
standard tools. The expense and time delay involved in mobilising specialised contractor
personnel are avoided;
• there is no requirement for underwater welding.
The disadvantages of this technique are:
• the lifting, welding and lowering operation is vulnerable to environmental conditions;
• careful planning and strict compliance with the predetermined lifting and lowering
procedures are vital to avoid overstressing the pipeline and riser;
• greater adjustability in the riser clamps is required because the riser cannot be moved
fore and aft once it is welded to the pipeline.
3.3.1 General
In most cases, tie-in of the pipeline to the offshore facility is achieved by inserting an
expansion spoolpiece. The purpose of the spoolpiece is to absorb expansion loadings, and
accommodate the installation tolerance on the pipeline.
The spoolpiece connections may be made up using one or a combination of the following
methods:
• mechanical connectors;
• flanged tie-in using RTJ swivel ring flanges; or
• hyperbaric welding.
These tie-in methods are further described below.
Subsea flanges and fittings should be bolted together using hydraulic tensioning
equipment. Hydraulic bolt tensioning equipment is used on either side of a flange to stretch
the bolts to a predetermined tension. With the tension maintained on the bolt, the nuts are
turned down onto the flange, to bar tight, prior to relaxation of the equipment. In this way
the flange can be tensioned to meet the service load. Washers are not used on subsea
pipe-to-pipe joints as these are prone to contact corrosion, which causes the bolts to
slacken with time.
• position different production functions along the spine, so that future extension of any
function is perpendicular to the spine;
• allow for new functions to be installed along the spine.
A dedicated riser platform may be installed to supply additional riser capacity (with scraper
barrels and manifolds) and/or to improve safety and reduce the overall risk levels on
production facilities.
For new developments and extensions of existing complexes a careful study of the new
layout should be made in conjunction with anchor patterns (especially the drilling rigs),
pipeline approaches, approach path for jack-up rigs and supply boat mooring.
4.3 SAFETY
The design shall include a safety assessment which shall quantify the effect of the risers on
platform safety and may include the use of risk analysis to determine the need for additional
protective measures. Consideration should be given to the use of cost-benefit analysis to
assess the relative merits of different protective measures.
The requirement for and location of ESD valves should be addressed as part of the
development of the platform specific safety case.
Any risk analysis performed shall take into account analysis of the risk from both natural
and man-made hazards. Natural hazards shall include but not be limited to corrosion
attack, marine life attack, extremes of temperature and environmental conditions. Man-
made hazards shall include but not be limited to platform loading and off-loading
operations, vessel activities, dragged anchors, trawl gear, abrasion by cables and chains,
impact by vessels and dropped objects.
DEP 31.40.10.10-Gen.
December 1999
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5. DESIGN DATA
5.3.1 Seawater
• water density;
• water kinematic viscosity;
• marine growth elevations, thickness and density.
5.3.4 Currents
• maximum current velocity for a range of current directions (usually 8), heights above
seabed (usually every 10 m) and return period (usually 1 and 100 years);
• relationship between the occurrence of wave-induced currents and the steady currents;
• the number of hours of occurrence per year for the ranges of steady current from zero to
the maximum steady current. These data are used for riser span fatigue calculations.
5.3.5 Waves
• maximum wave height for a range of directions (usually 8) and a range of return periods
(usually 1 and 100 years);
• the most probable wave period associated with each maximum wave height;
• the number of waves per year for ranges of wave height from zero to the maximum
wave height.
DEP 31.40.10.10-Gen.
December 1999
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5.4.1 Wind
• maximum wind velocity for return periods of 1 and 100 years;
• maximum and minimum ambient air temperatures.
5.4.2 Ice
• the maximum thickness of icing on risers;
• the maximum thickness and occurrence of permanent ice;
• the maximum velocity and occurrence of pack ice.
5.5 EARTHQUAKE
In regions of the world prone to earthquakes, the response of the platform under the
100-year seismic event is required.
5.7 DIRECTIONALITY
Given sufficient hydrographic data, it is acceptable to account for the incident angle of wave
and current attack on the pipeline/riser system. Tidal currents are strongly directional. If the
wave and current data can be represented as a rosette, giving variation of wave height (or
current value) with direction for a given return period, then the resulting flow velocities may
be resolved perpendicular to the pipeline axis to give the (most critical) design loading
condition.
DEP 31.40.10.10-Gen.
December 1999
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6.5.1 General
The design of the pipeline and riser system shall consider the pipeline expansion due to the
effects of temperature and pressure. If pipeline expansion results in loads and stresses that
DEP 31.40.10.10-Gen.
December 1999
Page 21
exceed acceptable limits, an expansion loop or other method of reducing the expansion
effects shall be provided.
The pipe system shall be modelled using pipe and elbow elements. Node spacing shall be
carefully selected to provide adequate stress output summaries of critical locations (i.e.
pipeline elbow).
The riser guides and supports shall be modelled by applying restraints to the model with the
required degrees of freedom.
The thermal offset/soil friction interaction is complex and will be modelled by springs for
small movements of the spool, or forces for larger movements of the spool.
If overstressing due to hydrodynamic loads is predicted, then one or more of the following
should be adopted:
• relocation of clamps;
• use of additional clamps;
• increase in riser pipe material grade and/or wall thickness;
• use of anti-fouling coating and/or cleaning systems to reduce marine growth.
6.10 OVALISATION
The riser design shall ensure that pipe ovalisation, F, does not exceed 2.5%.
where:
and:
F = Ovalisation
Dmax = maximum OD
Dmin = minimum OD
The design shall consider ovalisation that results from pipe manufacture, external pressure
and pipe bending.
6.11 COLLAPSE
The riser design shall ensure the pipe is not subject to collapse/local buckling under any of
the load cases. Collapse results from excessive external pressure and/or pipe bending.
Appropriate safety factors against collapse are given in DnV Rules for Submarine Pipelines.
Note: Specialist advice should be sought when using cold-expanded linepipe as the DnV Rules underestimate
the effect of residual stresses.
as a whole. The analysis shall take account of interaction with nearby structural elements
and other risers.
If it is not possible to eliminate in-line vortex-induced vibration by design, then a fatigue
analysis shall be performed to demonstrate an acceptable fatigue life.
6.13 FATIGUE
The fatigue analysis shall consider fatigue damage from cyclic loadings due to pressure,
temperature, waves and vortex-induced vibration.
The riser pipe shall have a fatigue life of at least 10 (ten) times the intended service life.
Conservatively, six shutdown and start-up cycles per year shall be assumed when
assessing the fatigue life of risers.
DEP 31.40.10.10-Gen.
December 1999
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For retrofit risers, specific attention shall be given to the requirement for position adjustment
of supports to enable a stress-free riser installation. The required adjustment shall be
determined taking into account the following tolerances and accuracies:
• dimensional accuracy of as-built drawings;
• dimensional accuracy of measurements by divers;
• alignment accuracy of installed clamps;
• clamp closure tolerance;
• misalignment adjustment tolerance;
• riser fabrication dimensional control accuracy;
• riser transport and handling effect on dimensional variation.
At least 250 mm of adjustment should be provided in the riser clamp design in order to
accommodate the stack-up of tolerances. See (Figure 4) for configuration of clamp with
complete freedom of adjustment.
The design of riser guides shall also comply with the following requirements:
- the inside of the guide shall be provided with a ribbed polychloroprene liner vulcanised
to the guide body;
- the inside diameter of the lined riser guide shall be determined such that the riser can
move in its axial direction without significant restraint;
- risers coated with a polychloroprene coating at the location of riser guides shall be
provided with external Monel sheeting vulcanised to the riser coating over the length of
the riser guide and 250 mm at both sides in the installed condition. The length of the
Monel sheeting shall be sufficient to accommodate the requirement for adjustment of
vertical riser position during installation.
7.3 LOADING CONDITIONS
Supports shall be designed to resist the maximum loads from the risers, the support weight
and environmental loads on the support. Riser loads on the supports during hydrotesting of
the riser shall be taken into account when determining the support design loads.
The supports and supporting structures shall be designed to resist the combined loads from
the riser, environmental loads acting directly on the clamping structure and its weight for all
riser design conditions.
8. J-TUBE DESIGN
NOTE: Reducing the number of bends and bend angle and increasing the bend radii will reduce the friction
forces between riser and J-tube during pull-in and will lead to minimum pull-in and J-tube design loads.
Coefficient of friction
riser and seabed 0.4 to 0.6
riser and inside of the J-tube wall 0.3 to 0.65
pull cable and the inside of the J-tube wall 0.2 to 0.4
8.6 APPURTENANCES
These seals allow greater axial movement compared to simple diaphragm seals and,
by increasing the length of the sleeves, can cope with axial movement over half a
metre.
These types of seal are suitable for differential pressures of up to 2 bar.
e) Anchor type seal
This type of seal is based on the same principle as the conical rubber seal, with the
difference that the seal is kept in constant compression irrespective of the
movements/loads in the riser. This is achieved by an anchor flange which is attached
to the riser behind the conical seal. Two split flanges are attached behind the anchor
and tightened to the bellmouth. This prevents the riser from moving at the bellmouth,
so ensuring the integrity of the seal. As discussed, this system does not permit any
axial movement of the riser, but can accommodate relatively high differential
pressures.
9. FITTINGS
9.1 FLANGES
Flanges shall comply with DEP 31.40.21.34-Gen.
If bending moments, additional axial forces or shear forces occur at the location of the
flange connection, a behaviour (including the gasket with regard to leaking), stress and
bolting force analysis according to ASME VIII shall be carried out, taking into account all
relevant loading situations for the flanged connection.
For maintenance purposes, the operating manual for the pipeline system shall detail the
flange installation procedures used including the equipment required, the bolt pre-tension
forces to be applied and measurements to be made.
Consideration shall be made for the provision of profiled flange protectors to prevent
snagging by cables.
9.2 GASKETS
The gasket shall be a ring type gasket in accordance with ASME B16.20 and shall be made
of a material softer than the flange ring groove. The gasket material shall be chosen for
compatibility with the flange material and for the service conditions. Consideration should
be given to the use of ring joint inlays and corrosion-resistant materials for the gaskets.
Consideration should also be given to the use of coatings on the gaskets to improve
corrosion resistance.
9.3 BOLTING
Bolting shall comply with DEP 30.10.02.11-Gen.
Note: The preferred materials for standard applications are ASTM A 193-B7 and ASTM A 194-2H for non-sour
service conditions, and ASTM A 193-B7M and ASTM A194-2HM for sour service conditions. For special
applications, e.g. low temperature, other materials may be required.
9.4 VALVES
Valves for offshore pipelines shall comply with API 6D.
Submarine valves should not be included in offshore pipeline systems because of the
difficulty of inspection and maintenance. To facilitate maintenance, valves shall be either
flanged both ends or be of the top-entry type and be suitably mounted for ease of access.
Piggability requirements shall be taken into account in the selection of valves.
9.5 BENDS
All long-radius riser bends shall comply with DEP 31.40.20.33-Gen.
Consideration should be given to the use of long tangents to provide cut material for fit-up
offshore.
DEP 31.40.10.10-Gen.
December 1999
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10.1 GENERAL
The service conditions throughout the design life of the pipeline shall be established to
permit the selection of suitable materials based on a technical and economical evaluation.
The requirements for pipeline materials shall comply with DEP 31.40.00.10-Gen.
10.2 LINEPIPE
Amended per
Circular 16/02
Carbon steel linepipe shall comply with DEP 31.40.20.37-Gen.
Coal tar enamel or coal tar epoxy coating systems shall not be used.
Corrosion coating systems shall be in accordance with the DEPs listed in the above table or
project-specific specifications.
Field joint coating systems shall be compatible with and have good adhesion to the mill-
applied coating, and shall be stored and applied in accordance with the Manufacturer’s
recommendations.
DEP 31.40.10.10-Gen.
December 1999
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Thermal insulation materials and their properties shall only be selected in full consultation
with the Principal, taking into account the long-term degradation of mechanical and thermal
properties at operating conditions, such as service temperatures and (external hydrostatic)
pressures.
The riser system should be designed with regard to future inspection, maintenance and
repair.
If intelligent pigs are to be used for internal inspection, bend radii shall meet the following
requirements:
Nominal pipe diameter, D, Minimum bend radius
(mm)
≤ 100 10 D
150 to 250 5D
≥ 300 3D
Additionally, if intelligent pigs are to be used, the pipeline internal diameter should ideally
be constant throughout, including valves, flanges, tees and other fittings.
Variations in internal diameter (Di) cannot always be avoided in local areas of limited
length, e.g. pipeline equipment such as valves. If changes in Di occur at the location of
equipment, pup pieces shall be used with a Di of the equipment. These pup pieces shall
have tapers to the pipeline Di with at least a 14 degree transition angle, measured from the
axis of the pipe (i.e. a taper of 1:4).
Consideration should be given to the requirement for possible riser replacement, in the
event this becomes necessary at some time during the life of the structure. If replacement
is not possible, as for example with a gravity based structure, consideration should be given
to the provision of a spare riser.
As far as practicable, the risers should be located to enable easy access for inspection,
maintenance and repair purposes. Consideration should be given to diver and remote
operated vehicle access throughout the length of the riser. Riser supports should be
avoided in the splash zone since they hinder inspection and may result in additional
corrosion.
DEP 31.40.10.10-Gen.
December 1999
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14.1 GENERAL
Documentation is produced at all stages during the life of a pipeline, from design to
abandonment. All essential documentation should be retained, be accessible and be
regularly updated, as required, throughout the life of the riser system.
15. REFERENCES
SHELL STANDARDS
Index to DEP publications and standard DEP 00.00.05.05-Gen.
specifications
Metallic materials – selected standards DEP 30.10.02.11-Gen.
Design of CP systems for offshore pipelines DEP 30.10.73.32-Gen.
Pipeline engineering DEP 31.40.00.10-Gen.
Amended per
Circular 16/02
AMERICAN STANDARDS
Pipeline valves API 6D
Issued by:
American Petroleum Institute
Publications and Distribution Section
1220 L Street Northwest
Washington DC. 20005
USA
ASME Boiler And Pressure Vessel Code:
Section VIII: Rules for construction of pressure ASME VIII
vessels
Metallic gaskets for pipe flanges ASME B16.20
Issued by:
American Society of Mechanical Engineers
345 East 47th Street
New York NY 10017
USA
Philadelphia
PA 19103
USA
NORWEGIAN STANDARDS
DnV rules for submarine pipeline systems
Issued by:
Det Norske Veritas
P.O. Box 300
N-1322 Høvik
Norway
NOTE: Most referenced external standards are available to Shell users on the Shell Wide Web at address
http://sww.shell.com/standards.
DEP 31.40.10.10-Gen.
December 1999
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APPENDIX 1 FIGURES
PRESSURE OF SEAL
WHERE:
Ps = Differential pressure at seal