Professional Documents
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Nger Ko Nccal 00 39082
Nger Ko Nccal 00 39082
PROJECT NAME
DOCUMENT TITLE
DOCUMENT NUMBER
NGER-KO-NCCAL-00-39082
Revision Response
Rev Date Originator Reviewer/Endorser Approver
Description Code
TABLE OF CONTENTS
1. INTRODUCTION.............................................................................................................5
1.1. Purpose of this Document ...................................................................................6
1.2. Unit of Measurements .........................................................................................7
2. APPLICABLE CODES, EXXONMOBIL GPS AND STANDARDS ................................8
2.1. Specification, Codes and Standards ...................................................................8
2.2. ExxonMobil GPs and Specification .....................................................................8
2.3. Contractors Project Documents ..........................................................................9
2.4. Contractors Project Drawings ..............................................................................9
2.5. Order Of Precedence ..........................................................................................9
3. ACRONYMS AND TERMS ...........................................................................................10
4. ABBREVIATION ...........................................................................................................11
5. INSTRUMENT AIR DRYER STRUCTURAL SUPPORT DESIGN ...............................12
5.1. Design Data and Assumptions ..........................................................................12
5.1.1. General ..................................................................................................12
5.1.2. Wind Data ..............................................................................................13
5.1.3. Design Requirements ............................................................................14
5.1.4. Global Coordinate System .....................................................................14
5.1.5. Instrument Air Dryer Description ............................................................15
5.1.6. Analysis Basis ........................................................................................15
5.1.6.1 Analysis..................................................................................................15
5.1.6.2 Allowable Stress ....................................................................................16
5.1.6.3 Deflection ...............................................................................................16
5.2. Computer Model ................................................................................................17
5.2.1. Axis System (Modelled section of deck beams) ....................................17
5.2.2. Model Geometric View ...........................................................................18
5.2.2.1 Model 3D View .......................................................................................18
5.2.2.2 Member Group & Sections.....................................................................19
5.2.2.3 Support/Boundary Conditions ................................................................21
5.2.2.4 Effective Length Factor (K-value) ..........................................................21
5.3. Loading..............................................................................................................22
5.3.1. Elementary Load Cases.........................................................................22
5.3.1.1 Dead Load .............................................................................................22
5.3.1.2 Live Load ...............................................................................................23
5.3.1.3 Wind Load ..............................................................................................24
5.3.2. Load Combination ..................................................................................24
5.3.1.4 Basic Loads ...........................................................................................25
5.3.1.5 Pre – Load Combination Loads .............................................................26
Doc. Number
DECK INTEGRITY NGER-KO-NCCAL-00-39082
EHRA PERFORMANCE
ASSESSMENT
IMPROVEMENT INITIATIVE CALCULATION REPORT Revision: C
PROGRAM Date: 27-10-2023
Unclassified Page 4 of 41
1. INTRODUCTION
Erha field was developed in 2006 and consists of a Floating, Production, Storage and
Offloading (FPSO) vessel connected to a subsea architecture and has a production capacity
of 210kbd. Over the service years, reliability of the Hydro-cyclone and Instrument air systems
have dropped. This scope of work is to help improve the reliability of the asset associated with
the hydro-cyclone and Instrument air Systems to deliver expected production at 80kbd. The
specific scope includes:
The Scope of Work covers detailed engineering design, materials selection for retrofit of
Hydro-cyclone. Contractor shall produce IFC drawings and documentations resulting from the
detailed engineering. Contractor shall also carry out as-building, updating and developing all
process, mechanical, instrumentation, electrical and structural drawings affected by the
modification scope.
Carry out fitness for service assessment on the existing skid and identify all the spools and
items on existing hydro cyclone skid that are in bad condition using the site findings already
done by client after validation. All items on the skid that are still in good condition shall be re-
used e.g., the pressure safety vales are in good physical condition but shall be re-used after
successful integrity test.
At the completion of the brownfield site visit, contractor shall produce a set of marked drawings
showing sections of the skid for replacement.
Carry out material study and review to produce specification(s) that will be less prone to the
highly corrosive environment on Erha (this includes all aspects of the installations on the skid)
Provide data sheet and specifications for all the valves on the skid
Replace corroded installed kit on skid e.g. (pipe supports, instrument stand etc).
Doc. Number
DECK INTEGRITY NGER-KO-NCCAL-00-39082
EHRA PERFORMANCE
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IMPROVEMENT INITIATIVE CALCULATION REPORT Revision: C
PROGRAM Date: 27-10-2023
Unclassified Page 6 of 41
The Scope of Work covers detailed engineering design, materials selection for new higher
capacity instrument air package. Contractor shall produce IFC drawings and documentations
resulting from the detailed engineering. Contractor shall also carry out as-building, updating
and developing all process, mechanical, instrumentation, electrical and structural drawings
affected by the modification scope.
At the completion of the brownfield site visit, contractor shall produce a set of marked drawings
showing sections of the existing structural and piping members that will be modified to
incorporate the new higher capacity dryers with in-built dew point analyzer.
Identify all the non-functioning or bad instruments and produce datasheets and specifications
as applicable.
Demolish items not in service on the deck to create space for the new higher capacity air dryer
Demolish the existing instrument air dryer and associated piping, design for installation of new
higher capacity dryers and integrate new kit to the existing infrastructure (wet air, dry air and
heat exchange systems).
Liaise with ERHA operations to provide specifications for new air compressors
Produce IFC drawings to hook up the dry and wet air to the heat exchanger and the air receiver
respectively.
Produce other detailed engineering deliverables as required to achieve scope of work.
Replace defective instrumentation, field monitoring devices for instrument air compressors.
This document presents the structural support design calculation for the proposed new
Instrument Air Dryer on “module E” in Erha.
This design calculation will consider the strength of the deck beams directly supporting the
new Instrument Air Dryer Package.
Doc. Number
DECK INTEGRITY NGER-KO-NCCAL-00-39082
EHRA PERFORMANCE
ASSESSMENT
IMPROVEMENT INITIATIVE CALCULATION REPORT Revision: C
PROGRAM Date: 27-10-2023
Unclassified Page 7 of 41
The units shown below (SI units in general) shall be used as the design units and all values
quoted shall be in these units. It is permissible to show alternative values and units as
indicated in the brackets only, after the design unit, when it is believed desirable. The size of
the unit shall be appropriate to the value being measured i.e. mm - m - km.
Description Unit
Length m (mm or km)
Area m²,
Density kg/m³
Yield Strength N/mm²
Temperature C
Force KN
• AISC ASD: American Institute of Steel Construction Manual 9th and 13th
Edition
• ASCE/SEI 7-10: Minimum Design Loads for Building and other Structures
The following are the GP specifications referred to in various parts of this document. Further
reference should also be made to Supplements relevant to the GPs below.
• GP29-01-45: Upstream Structural Material for Deck and Jackets and Topsides
• GP 29-01-03: Material Selection for Upstream and Midstream Facilities and Equipment
Doc. Number
DECK INTEGRITY NGER-KO-NCCAL-00-39082
EHRA PERFORMANCE
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IMPROVEMENT INITIATIVE CALCULATION REPORT Revision: C
PROGRAM Date: 27-10-2023
Unclassified Page 9 of 41
priority:
Should there be any conflict between these specifications, codes and standards, the more
stringent requirements shall take precedence and the latest edition of each code or standard
shall be applied.
Doc. Number
DECK INTEGRITY NGER-KO-NCCAL-00-39082
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Term Definition
4. ABBREVIATION
• GP Global Practice
• STR Structural
5.1.1. General
The design will check the existing and new deck framing beams that are directly supporting
the Instrument air dryer package for its strength capacity.
All loads derived for the purpose of this design have arrived at predominantly using the
guidelines of GP-25-01-01, API RP 2A WSD, AISC 360 and specifications given in the basis
of design. The Instrument air dryer weight is assumed to be 20tons as indicated in Erha –
Instrument Air Dryers Upgrade Scope of Work documents.
Figure 1.0 below shows the location of the proposed new Instrument air dryer on “module E”
also see ‘’ NGER-KO-NDDET-00-39081- Deck Modification_ Detail Structural Drawings’’.
Figure 1.0 – Deck Framing Plan Showing Proposed Air Dryer Location
The above figure shows the proposed location for the Instrument air dryer. The instrument air
dryer is located top side module ‘E’ between gridline ‘E1’ and ‘E2’ and mid-way between
gridline ‘A’ and ‘B’.
SACS 5.7 structural tool shall be used for the analysis and design of the structural elements.
Doc. Number
DECK INTEGRITY NGER-KO-NCCAL-00-39082
EHRA PERFORMANCE
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IMPROVEMENT INITIATIVE CALCULATION REPORT Revision: C
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Wind forces is calculated based on API RP-2A WSD formulations for a 1-year cycle
for operating conditions and a 100-yr cycle for extreme storm conditions as per GP
25-01-01U.
It corresponds to a 1-hour mean wind speed with a 3-sec gust at 10m above sea level
for individual members and a 5-sec gust for equipment skids less than 50m in length.
With reference to “NGER-WG-NBDES-SD-31747_Structural Design Basis” the below
wind speed is utilized.
00
900 2700
1800
Doc. Number
DECK INTEGRITY NGER-KO-NCCAL-00-39082
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The Instrument air dryer support shall be designed according to the requirements of
codes and standards defined in section 2.1 above. The input data and assumptions
for the design shall include but not limited to the following:
SACS 5.7 Structural tool shall be used for the analysis and design of the structural
elements:
The coordinate system used in the SACS model will be chosen as follows:
The instrument air dryer is located on the module E level EL (+) 118500mm T.O.S, between
gridline ‘E1’ and ‘E2’ and between gridline ‘A’ and ‘B’. The width of the instrument air dryer
base skid is 1.981m (outer dimension) lying between 5.045m and 7.374m away from grid ‘A’
and grid ‘B’ respectively. The length of the Instrument air base skid is 6.700m lying between
0.720m and 2.580 away from grid ‘E1’ and ‘E2’ respectively, as shown in figure below.
Assumed height of the instrument air dryer is 2.5m.
The Instrument air dryer is raised above the grating deck with steel deck pads.
Figure 2.0 – Deck Framing Plan Describing Proposed Instrument Air Dryer Dimension
5.1.6.1 Analysis
The instrument air dryer structural support analysis corresponds to the structural analysis
when the instrument air dryer is installed and operational.
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EHRA PERFORMANCE
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The design load of the analysis shall be the self-weight of the supporting framing beams
including 10% contingency, weight of the instrument air dryer including 10% contingency, live
load (to take care of weight during maintenance) and wind load.
For simplicity, the analysis will only check the framing beams directly supporting the instrument
air dryer for strength.
The boundary condition for the analysis is described in section 5.2.2.3 below.
The analysis is carried out for the operating and extreme environmental conditions.
Stresses in steel shall conform to requirement of AISC 360 and API RP 2A WSD. The
operating allowable stresses are the AISC basic allowable stresses:
Allowable stress
Design Condition
multiplier ratio
In-service
Operating condition 1.0
Extreme condition 1.33
5.1.6.3 Deflection
Deflection of structural members relative to their end supports shall be in accordance with GP
25-01-01. The below table shows the deflection limits for the structural elements
The section of deck beams that are supporting the Instrument air dryer is modelled in SACS.
Also modelled is the idealised instrument air dryer packaged (assumed to be a box structure,
considered to be dummy elements) to effectively capture the environmental load effect, and
the connecting members to connect the instrument air to the deck beam (also considered as
dummy elements).
E1
Platform North
0.785m 1.781m 2.433m 2.540m 2.460m
6.7m
0.810m
1.981m
1.354m
1.536m
0.900m
The 3D view of the model is shown below. The model shows existing framing beam, new
framing beams, instrument air dryer (as dummy) and connections between deck and dryer
skid (as dummy).
Existing Beams_EB5
(W14 X38) Existing Beams_EB1
New Beams_NB
(WPG 1200)
(W14 X38)
Existing Beams _EB2
(W16 X45)
Figure 5.0 – 3D Model showing Instrument Air Dryer and base skid
The modelled framing beams are supported by the existing non modelled girder beams. The
support locations are all considered as pinned as shown below.
111000
111000
111000
111000
The modelled framing beams are supported by the existing non modelled girder beams. The
support locations are all considered as pinned as shown below.
The effective length coefficients for SACS analysis and design shall be as follows:
Ky Kz
5.3. Loading
The dead weights have been considered in two scenarios – Modelled dead weight and un-
modelled dead weight.
All dead weight has been factored with partial safety factor of 1.1 to account for unforeseen
weights.
This loading includes the dead weight of the modelled framing beams which is automatically
generated by the computer model.
The dead weights have been factored by 1.1 in the SACS model for worst load effect.
This loading includes the weight of the Instrument air dryer and base skid components. Since
there is no available OEM information about the weigh, we assumed a total load of 20tons as
stated in the scope of work document.
The weight is factored by 1.1 in the SACS model for worst load effect (contingency).
From the SACS file, total un-factored dead weight (EQW) = 199.2806kN
A uniform distributed live load intensity of 5.0kN/m2 has been applied on the modelled framing
beams to account for maintenance purpose. The deck beams are divided to 14 difference
areas, so that the live load (area load) can be easily distributed to those area
The table below summarized the live load and its application.
Framing Uniform
Load beam/area Live Total Applied
Load Case Dimension Load Load Live load
Case Name in Distribution
Model Length Width (kN)
kN/m2
(m) (m)
Area Load on
201 LLW1 5.001 0.884 5.0 22.104
defined area.
Area Load on
202 LLW2 5.0 1.097 5.0 27.425
defined area.
Area Load on
203 LLW3 1.562 0.999 5.0 7.802
defined area.
Area Load on
204 LLW4 4.002 0.967 5.0 19.349
defined area.
Area Load on
205 LLW5 2.541 1.191 5.0 15.131
defined area.
Area Load on
206 LLW6 1.622 1.541 5.0 12.497
defined area.
Area Load on
207 LLW7 4.002 0.967 5.0 defined area. 19.349
Area Load on
208 LLW8 2.541 1.012 5.0 12.857
defined area.
Area Load on
209 LLW9 1.622 0.662 5.0 defined area. 5.368
Area Load on
210 LLW10 1.349 0.999 5.0 defined area. 6.738
Area Load on
211 LLW11 4.002 0.977 5.0 defined area. 19.549
Area Load on
212 LLW12 5.0 1.032 5.0 defined area. 25.8
Area Load on
213 LLW13 5.001 0.817 5.0 defined area. 20.429
Area Load on
214 LLW14 2.203 0.837 5.0 defined area. 9.219
The wind load will be automatically generated by SACS 5.7 with the appropriate wind speed
for operating and extreme condition in accordance with API RP 2A-WSD.
00
900 2700
1800
Operating wind loads are generated from the operating wind speed for 1-year return period of
33.8m/s at 10m (see basis of design).
Extreme wind loads are generated from the operating wind speed for 100-year return period
of 41.4m/s at 10m (see basis of design).
Loading have been combined for operating and extreme environmental conditions in
accordance with standards and specification stated in section 2.1 above and the structural
design basis to ensure worst loading effect is captured.
Note that dead loads applied in the model have been factored with partial safety factor of 1.1
in all cases.
Doc. Number
DECK INTEGRITY NGER-KO-NCCAL-00-39082
EHRA PERFORMANCE
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IMPROVEMENT INITIATIVE CALCULATION REPORT Revision: C
PROGRAM Date: 27-10-2023
Unclassified Page 25 of 41
The pre-combination load is considered for dead loads and live loads.
Load
Des. SELW EQW
Case
Dead
DLSM Load 1.0 1.0
Sum
Live
LLW Load 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0
Sum
Load
Combination
Case
DLSM LLW P000 P045 P090 P135 P180 P225 P270 P315
Load
Combination
Case
DLSM LLW E000 E045 E090 E135 E180 E225 E270 E315
The AISC 360/API RP 2A-WSD code for member stress of support beams are given hereafter.
Below table shows the maximum stress ratio for each member group for Operating condition.
APPLIED STRESSES
MAX. UNITY CHECK
DISTANCE
GROUP ID
CRITICAL
MEMBER
SHEAR-Y
SHEAR-Z
(N/mm2)
(N/mm2)
(N/mm2)
(N/mm2)
(N/mm2)
BEND-Y
BEND-Z
AXIAL
EB2 0052-0028 CO07 0.47 0.0 -0.11 40.58 49.46 -28.20 -7.92
NB 0057-0049 CO03 0.1 0.3 0.04 -0.01 -0.16 -2.23 -26.46
Table 12.0: Maximum Stress Ratio _ Operating Condition
From the above unity ratio check, the maximum utilization ratio for operating condition does
not exceed the allowable value of 1.0. The highest value obtained is 0.47 as shown in the
table 12.0 above and figure 14.0 below:
Also, find hereafter the maximum stress ratios for Extreme condition
APPLIED STRESSES
MAX. UNITY CHECK
DISTANCE
GROUP ID
CRITICAL
MEMBER
SHEAR-Y
SHEAR-Z
(N/mm2)
(N/mm2)
(N/mm2)
(N/mm2)
(N/mm2)
BEND-Y
BEND-Z
EB2 0052-0028 CE07 0.48 0.0 AXIAL
-0.12 40.73 49.77 -28.31 -8.03
NB 0057-0049 CE03 0.1 0.3 0.04 -0.01 -0.32 -2.27 -26.49
Table 13.0: Maximum Stress Ratio _ Extreme Condition
From the above unity ratio check, the maximum utilization ratio for Extreme condition does not
exceed the allowable value of 1.0. The highest value obtained is 0.48 as shown in table 13.0
above and figure 15.0 below:
The summary of the maximum joint displacement of the support structure is shown in the
tables below with respect to Extreme conditions.
DISPLACEMENT
LOAD COND JOINTS MILIMETERS
DEF(X) DEF(Y) DEF(Z)
CE01 0024, 0003, 0050 0.35 -0.15 -3.33
CE02 0024, 0029, 0050 0.35 0.18 -3.32
CE03 0024, 0029, 0050 0.35 0.19 -3.32
CE04 0024, 0029, 0050 0.35 0.18 -3.32
CE05 0024, 0003, 0050 0.35 -0.15 -3.33
CE06 0024, 0003, 0050 0.35 -0.18 -3.34
CE07 0024, 0003, 0050 0.36 -0.19 -3.35
CE08 0024, 0003, 0050 0.36 -0.18 -3.34
From the table above the maximum vertical joint deflection is 3.35mm occurs on joint 0050 for
extreme condition, beam length is 5001mm.
WIND
WIND D 33.800 135.00 AP08
LOADCNP180
WIND
WIND D 33.800 180.00 AP08
LOADCNP225
WIND
WIND D 33.800 225.00 AP08
LOADCNP270
WIND
WIND D 33.800 270.00 AP08
LOADCNP315
WIND
WIND D 33.800 315.00 AP08
LCOMB
LCOMB LLW 201 1.0000202 1.0000203 1.0000204 1.0000205 1.0000206 1.0000
LCOMB LLW 207 1.0000208 1.0000209 1.0000210 1.0000211 1.0000212 1.0000
LCOMB LLW 213 1.0000214 1.0000
LCOMB DLSM 102 1.0000101 1.0000
LCOMB C001 DLSM1.0000LLW 1.0000P0001.0000
LCOMB C002 DLSM1.0000LLW 1.0000P0451.0000
LCOMB C003 DLSM1.0000LLW 1.0000P0901.0000
LCOMB C004 DLSM1.0000LLW 1.0000P1351.0000
LCOMB C005 DLSM1.0000LLW 1.0000P1801.0000
LCOMB C006 DLSM1.0000LLW 1.0000P2251.0000
LCOMB C007 DLSM1.0000LLW 1.0000P2701.0000
LCOMB C008 DLSM1.0000LLW 1.0000P3151.0000
LCOMB CE01 DLSM1.0000LLW 1.0000E0001.0000
LCOMB CE02 DLSM1.0000LLW 1.0000E0451.0000
LCOMB CE03 DLSM1.0000LLW 1.0000E0901.0000
LCOMB CE04 DLSM1.0000LLW 1.0000E1351.0000
LCOMB CE05 DLSM1.0000LLW 1.0000E1801.0000
LCOMB CE06 DLSM1.0000LLW 1.0000E2251.0000
LCOMB CE07 DLSM1.0000LLW 1.0000E2701.0000
LCOMB CE08 DLSM1.0000LLW 1.0000E3151.0000
END
**PHY1**T0018-0028 THRO0018-0052 MEM0052-0028 MEM
**PHY1**T0022-0029 THRO0022-0006 MEM0006-0029 MEM
**PHY1**T0024-0025 THRO0024-0053 MEM0053-0025 MEM
**PHY1**T0024-0031 THRO0024-0005 MEM0005-0031 MEM
**PHY1**T0036-0037 THRO0036-0048 MEM0048-0037 MEM
**PHY1**T0037-0038 THRO0037-0050 MEM0050-0038 MEM
**PHY1**T0039-0040 THRO0039-0059 MEM0059-0040 MEM
**PHY1**T0042-0043 THRO0042-0047 MEM0047-0049 MEM0049-0043 MEM
**PHY1**T0048-0047 THRO0048-0056 MEM0056-0047 MEM
**PHY1**T0050-0049 THRO0050-0057 MEM0057-0049 MEM
**PHY1**T0051-0052 THRO0051-0055 MEM0055-0052 MEM
**PHY1**T0053-0054 THRO0053-0003 MEM0003-0054 MEM
**JNCV** 0 0 0 0 0 0 1
**GCOL** DM1M0 0 255 DM2M0 0 255 EB1M255 255 0 EB2M255 128 0
**GCOL** EB3M0 255 255 EB4M128 128 255 EB5M0 255 64 NB M255 0 128
END
* * * M E M B E R G R O U P S U M M A R Y * * *
AISC 2005 ASD / API RP2A-WSD
DM1 0006-0061 CE01 1.02 0.3 -33.68 -0.03-145.11 .15E+03.80E+04.18E+03.18E+03 C>.15B 0.3 0.3 0.85 0.85
DM2 0064-0066 CE03 1.04 0.0 1.10-117.55 38.51 .15E+03.13E+03.14E+03.23E+03 TN+BN 2.1 2.1 1.00 1.00
EB1 0031-0032 CE08 0.19 0.5 7.17 19.77 -11.35 .15E+03.92E+04.17E+03.23E+03 TN+BN 5.4 0.5 1.00 1.00
EB2 0059-0040 CE03 0.27 0.0 -10.93 28.31 -6.97 .15E+03.13E+05.16E+03.23E+03 CM+BN 0.4 0.4 1.00 1.00
EB3 0002-0007 CE03 0.07 0.0 0.27 -8.97 2.47 .15E+03.24E+04.16E+03.23E+03 TN+BN 5.0 0.7 1.00 1.00
EB4 0016-0017 CE07 0.11 0.0 -3.14 12.00 5.20 .14E+03.26E+04.16E+03.23E+03 CM+BN 1.6 1.6 1.00 1.00
EB5 0052-0028 CE07 0.48 0.0 -0.16 44.29 50.66 .15E+03.14E+05.16E+03.23E+03 CM+BN 0.4 0.4 1.00 1.00
NB 0051-0055 CE07 0.10 0.8 -8.38 8.43 4.85 .14E+03.33E+04.16E+03.23E+03 CM+BN 1.0 0.8 1.00 1.00