January 2016 K33: Pipeline Infrastructure and Design Confirming the Engineering Design Rationale Technical Transport K33: Pipeline Infrastructure and Design Confirming the Engineering Design Rationale IMPORTANT NOTICE The information provided further to UK CCS Commercialisation Programme (the Competition) set out herein (the Information) has been prepared by Capture Power Limited and its sub-contractors (the Consortium) solely for the Department of Energy and Climate Change in connection with the Competition. The Information does not amount to advice on CCS technology or any CCS engineering, commercial, financial, regulatory, legal or other solutions on which any reliance should be placed. Accordingly, no member of the Consortium makes (and the UK Government does not make) any representation, warranty or undertaking, express or implied, as to the accuracy, adequacy or completeness of any of the Information and no reliance may be placed on the Information. In so far as permitted by law, no member of the Consortium or any company in the same group as any member of the Consortium or their respective officers, employees or agents accepts (and the UK Government does not accept) any responsibility or liability of any kind, whether for negligence or any other reason, for any damage or loss arising from any use of or any reliance placed on the Information or any subsequent communication of the Information. Each person to whom the Information is made available must make their own independent assessment of the Information after making such investigation and taking professional technical, engineering, commercial, regulatory, financial, legal or other advice, as they deem necessary. K33: Pipeline Infrastructure and Design Confirming the Engineering Design Rationale Contents Chapter Title Page Executive Summary i 1 Introduction 2 2 Purpose 3 3 Overview 5 4 Development Consent Order 8 4.1 Development Consent Order Schedule 1 _________________________________________________ 8 4.2 Development Consent Order Works Plan ________________________________________________ 23 5 Onshore Pipeline Design 24 5.1 PD 8010 Part 1 Code of Practice Report ________________________________________________ 24 5.1.1 System and Safety _________________________________________________________________ 24 5.1.1.1 Public Safety and Protection of the Environment __________________________________________ 24 5.1.1.2 Design Factor _____________________________________________________________________ 25 5.1.2 Route Selection ___________________________________________________________________ 26 5.1.3 Mechanical Integrity ________________________________________________________________ 26 5.1.3.1 Process Conditions_________________________________________________________________ 27 5.1.3.2 Wall Thickness ____________________________________________________________________ 27 5.1.3.3 Corrosion Allowance________________________________________________________________ 27 5.1.3.4 Restrained Pipeline Combined Stress __________________________________________________ 27 5.1.3.5 Stability __________________________________________________________________________ 28 5.1.3.6 Spanning ________________________________________________________________________ 28 5.1.3.7 Upheaval Buckling Assessment _______________________________________________________ 28 5.1.3.8 Fatigue __________________________________________________________________________ 28 5.1.3.9 Ovality __________________________________________________________________________ 28 5.1.3.10 Road Crossings ___________________________________________________________________ 29 5.1.3.11 Bending _________________________________________________________________________ 29 5.1.3.12 Expansion and Flexibility ____________________________________________________________ 29 5.1.3.13 Anchor Blocks ____________________________________________________________________ 30 5.1.3.14 Trenchless Crossings _______________________________________________________________ 30 5.1.3.15 Hydrotesting ______________________________________________________________________ 30 5.1.3.16 Cover ___________________________________________________________________________ 31 5.1.4 Corrosion Management _____________________________________________________________ 31 5.1.4.1 External Coatings __________________________________________________________________ 31 5.1.4.2 Cathodic Protection (CP) ____________________________________________________________ 31 5.2 Pipe Laying and Routing Study _______________________________________________________ 32 5.2.1 Development Consent Order _________________________________________________________ 32 5.2.2 Construction Report ________________________________________________________________ 33 5.2.3 Code of Construction Practice ________________________________________________________ 33 5.2.4 Works Plans ______________________________________________________________________ 34 5.2.5 Crossing Schedule _________________________________________________________________ 34 5.2.6 Crossing Techniques _______________________________________________________________ 34 K33: Pipeline Infrastructure and Design Confirming the Engineering Design Rationale 6 Offshore Pipeline Design 35 6.1 PD 8010 Part 2 Code of Practice Report ________________________________________________ 35 6.1.1 Health Safety and Assurances ________________________________________________________ 35 6.1.1.1 Health Safety and the Environment ____________________________________________________ 35 6.1.1.2 Quality Assurance _________________________________________________________________ 36 6.1.1.3 Design, Construction and Commissioning Assurance ______________________________________ 36 6.1.1.4 Operation and Abandonment _________________________________________________________ 36 6.1.1.5 Plans and Drawings ________________________________________________________________ 36 6.1.2 Design – System and Safety _________________________________________________________ 36 6.1.2.1 Categorisation of Fluids _____________________________________________________________ 37 6.1.2.2 Pipeline Process Design _____________________________________________________________ 37 6.1.2.3 Public Safety and Protection of the Environment __________________________________________ 37 6.1.2.4 Route Selection ___________________________________________________________________ 37 6.1.3 Design – Mechanical Integrity ________________________________________________________ 37 6.1.3.1 Design Criteria ____________________________________________________________________ 37 6.1.3.2 Loads ___________________________________________________________________________ 38 6.1.3.3 Strength _________________________________________________________________________ 38 6.1.3.4 Stability __________________________________________________________________________ 40 6.1.3.5 Spanning ________________________________________________________________________ 40 6.1.3.6 Pipeline and Cable Crossings ________________________________________________________ 40 6.1.3.7 Leak Detection ____________________________________________________________________ 41 6.1.4 Design – Landfalls Risers and Tie-ins __________________________________________________ 41 6.1.4.1 Landfall __________________________________________________________________________ 41 6.1.4.2 Risers and Tie-ins__________________________________________________________________ 41 6.1.4.3 Subsea Connections and Valves ______________________________________________________ 42 6.1.4.4 Protection ________________________________________________________________________ 42 6.1.4.5 Pipeline Shutdown Systems __________________________________________________________ 42 6.1.5 Design Materials and Coatings ________________________________________________________ 42 6.1.5.1 Linepipe Selection _________________________________________________________________ 43 6.1.5.2 PIG Traps ________________________________________________________________________ 43 6.1.5.3 Insulation Joints ___________________________________________________________________ 43 6.1.5.4 Coatings _________________________________________________________________________ 43 6.1.6 Corrosion Management _____________________________________________________________ 43 6.1.6.1 Internal Corrosion __________________________________________________________________ 44 6.1.6.2 External Corrosion _________________________________________________________________ 44 6.1.7 Construction – Fabrication and Installation _______________________________________________ 44 6.1.8 Construction – Testing ______________________________________________________________ 44 6.2 Offshore Pipeline Design Reports _____________________________________________________ 44 6.2.1 Hydraulic Analysis _________________________________________________________________ 45 6.2.2 Route Selection ___________________________________________________________________ 45 6.2.2.1 Kilometre Points ___________________________________________________________________ 46 6.2.2.2 Route Description __________________________________________________________________ 46 6.2.2.3 Offshore Proposed Route ____________________________________________________________ 48 6.2.3 Geohazards ______________________________________________________________________ 48 6.2.3.1 Slope Failure _____________________________________________________________________ 49 6.2.3.2 Anchor Scarring ___________________________________________________________________ 49 6.2.3.3 Trawl Scarring ____________________________________________________________________