IBP1278_09

DETAILED FREE SPAN ASSESSMENT FOR MEXIHLÃO

FLOWLINES
Antonio Pereira1, Luciano Franco2, Uwa Eigbe3, Carlos Escudero4,
Carlos Bomfimsilva5

Copyright 2009, Brazilian Petroleum, Gas and Biofuels Institute - IBP

This Technical Paper was prepared for presentation at the Rio Pipeline Conference and Exposition 2009, held between September,
22-24, 2009, in Rio de Janeiro. This Technical Paper was selected for presentation by the Technical Committee of the event
according to the information contained in the abstract submitted by the author(s). The contents of the Technical Paper, as presented,
were not reviewed by IBP. The organizers are not supposed to translate or correct the submitted papers. The material as it is
presented, does not necessarily represent Brazilian Petroleum, Gas and Biofuels Institute’ opinion, or that of its Members or
Representatives. Authors consent to the publication of this Technical Paper in the Rio Pipeline Conference Proceedings.

Abstract
The subsea gas production system of Mexilhão Field SPS-35, Santos Basin, offshore Brazil, is composed basically of
two rigid 12.75”production flowlines approximately 21 km long installed in a fairly rough seabed. During the basic
design, the free span assessment was performed considering the maximum allowable free span length determined by the
response model proposed by DNV-RP-F105. This approach resulted in a large number of predicted free span requiring
corrections, leading to a higher capital cost for the project. In this sense, a detailed free span VIV fatigue assessment
was proposed, considering multi-spans and multi-mode effects and also the post lay survey data. The assessment
followed the DNV-RP-F105 recommendations for multi-spans and multi-mode effects, using Finite Element Analysis
to determine the natural frequencies, mode shapes and corresponding stresses associated with the mode shapes. The
assessment was performed in three stages, the first during the detailed design as part of the bottom roughness analysis
using the expected residual pipelay tension. The second stage was performed after pipelay, considering the post-lay
survey data, where the actual requirements for span correction were determined. Actual pipelay tension was used and
seabed soil stiffness adjusted in the model to match the as-laid pipeline profile obtained from the survey data. The first
and second stage assessments are seamlessly automated to speed up the evaluation process and allow for quick
response in the field, which was important to keep the construction vessel time minimized. The third stage was
performed once the corrections of the spans were made and the purpose was to confirm that the new pipeline
configuration along the supported spans had sufficient fatigue life for the temporary and operational phases. For the
assessment of all three stages, the probability of occurrence and directionality of the near bottom current was
considered to improve prediction of the design life. This paper presents the FE methodology and associated tools to
perform the detailed free span assessment of the Mexilhão flowlines, considering the design information, the post-lay
survey data and the as-built reports after span correction in order to accurately account for the multi-spans and multi-
mode effects in the span assessment procedure.

1. Introduction
The Mexilhão Field is located at a water depth of up to 500m in the Santos Basin, offshore Brazil. The project
consists of two rigid 12.75” OD infield gas production pipelines connecting the gas production manifold MSPG-MXL-
01, in water depths down to 500 m, to the fixed Platform PMXL-01. The subsea layout of the gas infield pipeline
system is shown in Figure 1. The fixed platform PMXL-1, located at a water depth of 172m, will export the gas through
a pipeline, to the gas treatment unit (GTU) in Caraguatatuba (Northern São Paulo State Coast).
The infield gas pipelines have been installed in the continental shelf break, which has a very irregular seabed
with large depressions and pockmarks along the pipeline route. The number and complexity of free spans for the
pipelines installed in these areas normally increases considerably due to the seabed roughness. In this case, the

______________________________
1
M.Sc. Mechanical Engineer - INTECSEA
2
M.Sc. Civil Engineer - INTECSEA
3
Ph.D. Civil Engineer - INTECSEA
4
Mechanical Engineer - PETROBRAS
5
M.Sc. Mechanical Engineer - INTECSEA
 Rio Pipeline Conference and Exposition 2009
conventional methods to determine maximum allowable span lengths to avoid VIV (Vortex induced vibration) leads to
a large number of free span requiring corrections, which in turn leads to higher capital cost for the project. Therefore,
the free spans evaluation and correction becomes a challenge and detailed free span assessment using FE analyses is
required to reduce the quantities and cost of free span correction instead of using simple analytical approaches.
The main objective of this paper is to present the methodology used in the design and post-lay assessment
considering the post-lay survey and as-built data, the probability of occurrence and directionality of currents and the
multi-spans and multi-mode effects. The design comprised of the following steps:
• Route selection based on pre-lay AUV seabed bathymetry data;
• Detailed free span assessment using pre-lay AUV seabed bathymetry data;
• Detailed free span assessment using the post-lay survey data (with out span correction)
• Detailed free span assessment based on free span correction works (as-built data with span correction features)

North Pipeline

South Pipeline

Figure 1: Subsea Layout of the 12.75” Rigid Infield Gas Production Pipelines

2. Design Phases
2.1. Route Selection

The route selection was performed using the AUV seabed bathymetry data from a corridor width of 180m and
based on a defined maximum allowable free span. The maximum allowable free span length was established following
the Fatigue Limit State (FLS) given by DNV-RP-F105 and Ultimate Limit State (ULS) criteria for load controlled
condition of DNV-OS-F101. These are based on the approximate response quantities which is simplified analytical
approach. .
The DNV FatFree (Ver. 10.0) software was used to determine the maximum allowable span length considering
the joint distribution of bottom current and direction of the region were applied. A single mode response and single
span boundary condition were considered in this step. Wave action has minimal effect in the water depths both
pipelines are installed. Maximum allowable free span lengths of 94m, 42m and 26m were determined for as-laid,
hydrotest and operational conditions respectively.
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A straight route with the lowest number of predicted free spans was selected for the north and south pipelines.
However, the number of predicted free spans was still relatively high and the potential cost for free span correction was
a major concern for the project. According to the results shown in Table 1, a total of 103 and 3 critical spans were
identified in operational and hydrotest conditions respectively. The critical spans are the spans with lengths larger than
the maximum allowable limit and with design gap exceeding 30% of the pipeline outside diameter.

Table 1. Number of predicted free Spans

Pipeline As-laid Hydrotest Operational
Condition Condition Condition
North Pipeline 0 1 48
South Pipeline 0 2 55
Total 0 3 103

Most of the free spans were identified after the KP 5.5 as shown in Figure 2 for south pipeline under
operational condition. The seabed between KP 0 and KP 5.5 is composed of soft clay, after KP 5.5 the seabed is
composed of medium sand soil. Along the sandy soil section, a number of spans were identified as non- isolated, i.e.
the adjacent spans were interacting and a multi-mode and multi-span behavior was observed. Consequently, the
allowable single-span and single-mode calculation could not be applied for the assessment of these spans. Therefore,
further detailed free span assessment considering the multi-span behavior using FE analysis was required.

Figure 2. Seabed profile vs. predicted span length for south route under operational condition

2.2. Detailed Free Span Assessment Based on Pre-Lay AUV Seabed Bathymetry Data

The detailed free span assessment was performed to consider a multi-span behavior but also to allow for a
better estimate of the requirements for free span correction with significant cost savings anticipated. The proposed
methodology also has the potential for post-lay assessment of the pipelines, which was also performed in this project as
presented below. The analysis was carried out following the DNV-RP-F105 recommendations for the evaluation of the
through-life pipeline integrity with regards to Fatigue Limit State (FLS) due to Vortex Induced Vibration (VIV). The
Ultimate Limit State (ULS) criterion was also applied using the load controlled criteria and the design factor given by
DNV-OS-F101. A high safety class was considered close to the fixed platform PMXL-1 and normal safety class was
considered for the rest of the pipeline.
A methodology was developed using FE approach and comprising three main steps:
• Bottom roughness analysis using the in-house program “SPAN-CALC”;
• Modal analysis using the in-house program “MODE-CALC”;
• Fatigue assessment using the in-house program “FATCALC”.
The purpose of the bottom-roughness analysis was to determine the initial static equilibrium configuration and
provide the input data for modal analysis by selecting the critical free span as presented in section 4. In this case, the
bottom roughness was already performed during the route selection phase, where the critical free spans and their

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characteristics such as, span length, design gap, location and shoulder length were identified. The critical spans were
selected as part of the process described in section 2.1 and are shown in Table 1.
After the selection of the critical spans, the modal analysis and fatigue assessment were performed, as
presented in sections 4 and 5 respectively. The modal analysis was performed to provide the critical cross-flow and in-
line natural frequencies and their respective mode-shapes.
The fatigue assessment was performed to calculate the damage along the span based on the stress range. The
allowable fatigue damage budget was allocated as 10% for installation phase (pipelay), 10% for temporary phase (as-
laid/empty, flooded and hydrotest condition) and 80% for the operational phase.
By using this methodology, the number of free span requiring correction was reduced to 74 spans; these spans
had through-life fatigue damage exceeding the allowable limits. Only three of these spans analyzed shall be mitigated
before hydrotest because two spans in the south pipeline and one in the north pipeline exceeded the ULS criteria during
hydrotest.

2.3. Detailed Free Span Assessment Based on the Post-Lay Survey Data

The detailed free span assessment based on the post-lay survey data is similar to the analysis performed using
the pre-lay AUV bathymetry data. However, the static bottom roughness analysis which is a predictive process is not
considered herein as the actual span characteristics can be deduced from the survey data. The critical free spans were
selected using the seabed and pipeline profiles provided by post-lay survey information. The post-lay survey
information is furnished in EXCEL format containing the TOP (top of pipe) measured from the surface, BOP (bottom
of the pipe) measured from surface, the mean seabed level away from the pipe and the adjacent seabed level
immediately beside the pipe. The adjacent seabed and BOP data were the information considered to identify the critical
spans.
The critical span identification was performed using the SPAN-CALC post-processor. This tool is also applied
in post-processing results of the bottom roughness analysis, in order to identify the critical spans, determine their
characteristics and create the input for the modal analysis, as presented in section 3. The Figure 3 shows the spans
along the pipeline.
Based on the post-lay survey data, a total of 91 critical spans for the operational phase were identified. This
consists of 49 and 42 spans for north and south pipelines, respectively. These observed critical spans from the post-lay
survey are not totally in agreement with the predicted number of spans determined from the pre-lay AUV bathymetric
data as shown in Table 1 and Figure 2. The reason is that the bottom lay tension considered in the design phase was
different from the pipelay tension used by installation contractor. The Figure 4 shows the bottom lay tension used in the
both phases.

Figure 3. Seabed profile vs. span length for south route considering the post lay survey information

The critical spans and adjacent sections, typically 300m-500m of pipeline on either side of each critical span,
are extracted from post-lay survey. The adjacent sections are required to allow the assessment of the multi-spanning
behavior and also to minimize the boundary condition effects on the modal analysis.
The first task is to calibrate the pipeline configuration from post-lay survey with static configuration by using
the in-house program MODE-CALC developed using the ANSYS program. This task involves fine tuning of the pipe
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lay tension and soil stiffness to achieve close agreement between the predicted pipeline configuration and the observed
profile from the post-lay survey.
After the identification and selection of the critical free spans, the modal analysis and fatigue assessment were
performed as presented in sections 4 and 5. The analysis was performed for a total of 49 and 42 critical spans for north
and south pipelines respectively under operational condition. These spans were identified as critical based on post-lay
survey data and the defined maximum allowable span lengths presented in section 2.1.
By using this methodology, the number of free span requiring correction was reduced to 46 spans. These spans
had through-life fatigue damage exceeding the allowable limits.

600

500
Bottom Lay Tension (kN)

400

300

200

100

0
0.00 2.00 4.00 6.00 8.00 10.00 12.00 14.00 16.00 18.00 20.00 22.00
KP (m )

Bottom Lay Tension used in the Design Phase Bottom Lay Tension used during the Installation

Figure 4. Bottom lay tension

2.4. Free Span Correction

The purpose this step is to evaluated the VIV fatigue damage of the critical spans after the free spans have
been corrected, i.e. after the remedial work. The supports were included in the FE model MODE-CALC by changing
the seabed profile at the support position and by increasing the vertical soil stiffness as shown in Figure 5. Then, the
modal and fatigue analyses was performed again in order to confirm that the free span correction is adequate and
effective. This step is performed for the span after it has been supported and the as-built survey is available.

Figure 5. Free span configuration with correction

3. Bottom Roughness Analysis

The purpose of the bottom-roughness analysis is to determine the initial static equilibrium configuration and
expected loading along the pipeline in the as-laid, temporary and operational conditions. An in-house FE program
(SPANCALC) has been developed in ANSYS to perform the pipeline bottom roughness analysis.
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The geometry of the free spans, including length, gaps, location and shoulders characteristics are all
determined based on bottom roughness analysis, which accounts for the initial static equilibrium configuration of the
pipeline in the as-laid condition followed by application of the subsequent load steps, such as flooding, hydrotesting,
dewatering, start-up, etc. The static analysis considers the non-linearity of the seabed stiffness and the effect of
geometric non-linearity within the pipeline.
In the SPAN-CALC program, elastic pipe elements (PIPE16) are used to model the pipeline. The pipeline-soil
interaction is modeled using a combination of nonlinear springs to represent the vertical seabed stiffness and also the
axial and lateral friction. The spring combination element (COMBIN39) is able to represent contacts, gaps (including
large displacement capability) and sliding between the pipeline and seabed. Contact occurs when the pipe and seabed
spring nodes intersect each other vertically. A 1m pipe element is normally considered satisfactory for the analysis.
The results of the span lengths for the pipeline during operational phase is compared to the corresponding
maximum allowable span length to allow identification of critical spans sections requiring further analysis for VIV
fatigue damage assessment.
A SPAN-CALC post-processor consisting of an Excel spreadsheet associated with visual basic application is
used for processing the results from the bottom roughness analysis in order to identify the critical spans and determine
their overall characteristics. The critical spans and adjacent sections, typically 300m-500m of pipeline at both sides of
each critical span are extracted from bottom roughness analysis with inherent information such as effective tension,
seabed and pipeline profiles, average gap of the central third of the span and the static bending moment. The 300m-
500m adjacent sections are required to allow for the multi-spanning behavior to be considered and also to minimize the
effects of boundary conditions on the results from the modal analysis.

4. Modal Analysis
An in-house program (MODE-CALC) for performing eigen-value analysis has been developed in ANSYS.
The MODE-CALC program is used to perform a multi-modal and multi-spanning eigen-value analysis to identify the
contributing vibration modes that may be activated during the life of the pipeline based on the expected current
velocities. The adjacent interacting spans from the near vicinities may also significantly influence the span vibration
and are considered in the modal analysis.
In this sense, seven (7) mode shapes are investigated, four (4) in-line modes and three (3) cross-flow modes,
which are selected based on the maximum curvatures arising from unit amplitudes displacement associated with the
natural frequency determined for the critical span. They are also selected considering the most probable current velocity
acting on the pipeline with reduced velocity higher than the onset value for in-line and cross flow respectively. This
criterion was selected to optimize the computer runs and it considers that the combination of higher curvatures with
lower frequency will lead to the most critical fatigue damage to the pipe. This was verified manually for several spans
before being accepted as fully satisfactory.
A MODE-CALC post-processor developed in Excel with associated visual basic application is used to retrieve
and select the mode-shapes and the natural frequencies derived from the modal analysis.

5. Fatigue Assessment
The fatigue assessment is performed using an in-house program (FATCALC) developed using MathCAD
software and supported by excel and visual basic application to extract results from the modal analysis and calculate the
damage to the pipeline in the temporary and operational phases. For each critical span, the following procedure is
adopted:
• For each of the reduced velocities associated with each mode shape, the maximum non-dimensional response
amplitudes, AY/D and AZ/D, are determined as per the response models given by DNV RP F105;
• The actual (de-normalized) in-line and cross-flow displacement amplitudes are calculated along the span;
• The pipeline curvatures (κ(x) = 1/ρ(x)) at each nodal location along the span, are then calculated based on the
actual displacement amplitudes using a finite difference algorithm;
• The in-line and cross-flow bending stress ranges at each nodal location along the span is determined from
linear bending theory. The combined inline and cross-flow VIV induced stress ranges due to multi-modal
behavior of the free span is calculated using the DNV response models.
• Fatigue Damage is calculated for all nodes along the span, based on multimodal response as recommended by
DNV-RP-F105, and using the accumulation law of Palmgren-Miner;
• Fatigue criterion is checked to verify the free span capacity to resist VIV during the expected design life.
• For completeness the ULS criterion is checked for local buckling in compliance with the combined loading as
per DNV-OS-F101 to ensure the free span capacity against ultimate limit state loading.
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The results from the proposed methodology and associated tools were compared with those from FATFREE
(Version 10.0) which is a software developed by DNV to determine fatigue lives of free spans according to DNV-RP-
F105. The validation which has been published in a paper presented by PEREIRA, A. C. P., et al. (2008) consists of
two tasks; the first is to verify the natural frequencies and peak curvature from the modal analysis program (MODE-
CALC) and the second is to verify the calculated fatigue life of free spans obtained from the fatigue calculation tool
(FATCALC).

6. Final Remarks
A methodology established for performing detailed free span assessment is used in a real-life project and
shown to be less conservative compared to the conventional approach. The results lead to a 50% reduction in the
number of free span requiring correction in order to avoid the fatigue failure as summarized in Table 2. This result was
obtained after detailed free span assessment based on the post-lay survey data where the bottom lay tension used was
the same as the pipelaying bottom lay tension.

Table 2. Summary of the number of critical free span and free span requiring correction
Phase Critical Free Span Free Span Requiring
Correction
Detail free span assessment based on AUV seabed data 103 74
Detail free span assessment based on post-lay survey data 91 46

It is important that the pre-lay AUV bathymetry data, soil properties and bottom lay tension need to be of good
quality for the accurate prediction of the free spans. In addition, it is important also to note that the oceanographic
information (metocean data) needs to be of good quality for successful application of the detailed free span assessment
methodology, i.e. high quality oceanographic information leads a more accurate fatigue damage assessment within the
spans.
It should be noted that it is important to re-perform the detailed free span assessment based on the post-lay
survey data, when post-lay survey is available, since information used during the design stage extracted from pre-lay
AUV bathymetry survey can differ significantly from the as-laid condition (i.e., post-lay). The as-laid survey will also
capture the actual pipeline configuration depending on the field-specific seabed conditions.
The different tools considered in this project have been seamlessly integrated to facilitate an automated and
quick implementation of the fatigue damage assessment procedure. This procedure allows for the analysis of the post-
lay survey in real-time for determination of requirements for free span correction in the field.

7. References
Det Norske Veritas, FATFREE Version 10.0, February 2006.
Det Norske Veritas, 2007, DNV OS-F-101, Offshore Standard: Submarine Pipeline Systems, October 2007.
Det Norske Veritas, 2006, DNV-RP F105, Recommended Practice: Free Spanning Pipelines, February 2006.
Fyrileiv, O., Mørk, K.J., and Chezhian, M., Experiences using DNV-RP-F105 in Assessment of Free Spanning
Pipelines, Proceedings of OMAE2005 24th International Conference on Offshore Mechanics and Arctic
Engineering, n. 67453, June 2005, Halkidiki, Greece.
PEREIRA, A. C. P., BOMFIMSILVA, C. T. P., EIGBE, U., FRANCO, L. D., VIEIRA, L. T. , In-place free span
assessment using finite element analysis, Proceedings of OMAE2008 27th International Conference on Offshore
Mechanics and Arctic Engineering, n. 57272, June 2008, Lisbon, Portugal.