WALL 5.

2
WALL THICKNESS SIZING - WALL

THEORETICAL MANUAL

COPYRIGHT NOTICE
Copyright Penspen Limited 1987-2001
This document refers to proprietary computer software which is protected by
copyright. All rights are reserved. Copying or other reproduction of this manual
or the related module is prohibited without prior written consent of Andrew
Palmer and Associates, Penspen Limited, Darpen House, Citadel Place, Tinworth
Street, London SE11 5EF.

Table of Contents

Table of Contents
1.

Introduction .................................................................... 1

2.

Module Overview ............................................................. 2

2.1. Objective............................................................................................. 2
2.2. Operation and Theory .......................................................................... 2
2.3. Limitations .......................................................................................... 3

3.

Theoretical Basis ............................................................. 4

3.1. Resistance To Internal Pressure (Hoop Stress Criteria) ........................... 4
3.2. Resistance To External Pressure ........................................................... 6

3.2.1. Timoshenko And Gere .................................................................. 7

3.2.2. Murphy and Langner .................................................................... 7
3.3. Pipe Eccentricity, Out of Roundness and Initial Ovalisation ..................... 8

3.3.1. DnV ............................................................................................ 8

3.3.2. API 5L ......................................................................................... 8
3.3.3. IP6.............................................................................................. 9
3.3.4. BS 8010 ...................................................................................... 9
3.4. Resistance To Propagating Buckle....................................................... 10
3.5. Maximum Diameter To Thickness Ratio ............................................... 12
3.6. Nominal Wall Thickness...................................................................... 13

3.6.1. Corrosion Allowance................................................................... 13

3.6.2. Manufacturing Tolerance ............................................................ 13
3.7. Test Pressure .................................................................................... 13

4.

API Standard Wall Thicknesses ..................................... 15

5.

Module Operation .......................................................... 16

6.

External Data File .......................................................... 17

Penspen Andrew Palmers

PLUSONE WALL 5.2

Table of Contents
6.1. Data File structure.............................................................................. 17
6.2. Example structure as supplied............................................................. 17
6.3. Customising the data in FIL1.DAT ....................................................... 18

7.

References ..................................................................... 19

Penspen Andrew Palmers

PLUSONE WALL 5.2

Chapter 1 Introduction

1.

Introduction

The program module WALL is part of a computerised pipeline design system,

called PLUSONE, developed by Andrew Palmer and Associates. The PLUSONE
system comprises a number of program modules as follows:

PROP
2PHF
LIQF
GASF
HYDR
HEAT
WALL
STAB
STB2
XPAN
SPAN
ANOD
CLAY
LAYS
QLAY
REEL
UPBK
MATS
LAYR
BUCK
GRID

Flow properties
Two phase flow analysis
Liquid flow analysis
Gas flow analysis
Hydrate formation analysis
Heat transfer analysis
Wall thickness sizing
Stability evaluation
Dynamic stability evaluation
Expansion analysis
Dynamic span evaluation
Anode size determination
Catenary evaluation
Lay stress evaluation
Quick lay stress evaluation
Reeling analysis
Upheaval buckling check
Materials selection
Lay rate estimation
Bending buckling
Coordinate conversion

Each program module can be used as a stand alone design module or can be
combined with other modules to form part of an integrated design system. This
manual describes the calculations carried out by the module WALL.
For operation and validation of the WALL module the user is directed to the WALL
validation manual.

Penspen Andrew Palmers

PLUSONE WALL 5.2

2.

Chapter 2 Module Overview

Module Overview
2.1. Objective

The objective of the WALL module is to calculate the minimum wall thickness that
will meet all the specified design code requirements.
2.2. Operation and Theory
To operate the WALL module the user must input the pipe data and operational
data and specify which design code to be used.
The WALL module will then calculate the wall thickness required to satisfy the
design code requirements. The following design codes can be specified:
IP66

Institute of Petroleum Pipeline Safety Code (UK).

DnV2

Det norske Veritas, Hvik, Norway (1981).

ASME 31.87

American Society of Mechanical Engineers, Liquid

Transportation Systems for Hydrocarbons, Liquid Petroleum
Gas, Anhydrous Ammonia, and Alcohols.

ASME 31.48

American Society of Mechanical Engineers, Gas Transmission

and Distribution Piping Systems.

BS 80109

British Standard 8010, Code of practice for pipelines. Part 3.

Pipelines subsea: design, construction and installation.

For a particular design basis one criteria will govern the wall thickness to be used.
The design criteria are as follows:-

Limiting hoop stress due to internal pressure.

Hydrostatic collapse due to external pressure.

Buckle propagation due to external pressure.

Specified maximum diameter to thickness ratio.

The criteria within the module include various published buckle propagation
evaluation methods, collapse, and internal pressure formulae.

Penspen Andrew Palmers

PLUSONE WALL 5.2

Chapter 2 Module Overview

The module WALL uses each of these criteria to calculate the minimum wall
thickness required for each before failure. Mill tolerance and corrosion allowance
are taken into account to obtain nominal wall thickness. The result is compared
with the nearest standard API 5L pipe size, in either imperial or metric.
2.3. Limitations
The WALL module has no known limitations, but care must be taken to keep the
parameters within realistic bounds.

Penspen Andrew Palmers

PLUSONE WALL 5.2

3.

Chapter 3 Theoretical Basis

Theoretical Basis

The following sections outline the analysis performed by the module in order to
arrive at the required wall thickness to satisfy static stress criteria and code
requirements. The module performs a series of calculations, taking into account
corrosion allowances and manufacturing tolerances, to arrive at the nominal pipe
wall thickness. Each section discusses the design criteria and options open to the
user. The sensitivity of each of the resulting wall thicknesses to the design
criteria selected is demonstrated graphically. A list of references for the formulae
used is given in Chapter 7.
3.1. Resistance To Internal Pressure (Hoop Stress Criteria)
Design codes and standards stipulate the maximum hoop stress in a pipeline shall
be limited to a specified fraction of yield stress.
The design pressure used in the analysis is based upon the maximum pressure
occurring at any point in the pipeline system. The maximum operating pressure
will be limited by pump capacity or reservoir pressure and determined during a
hydraulic analysis of the system. Design pressure may also take into account
transient surge pressure effects due to valve closure or shutting down of the
transfer pump.
The minimum or nominal wall thickness required to resist internal pressure may
be calculated from any of the four formulae below. It must be observed that DnV
and the ASME codes specifically refer to a nominal wall thickness while IP6 and
BS 8010 refer to a minimum wall thickness. If a minimum wall thickness is
specified then the nominal wall thickness may then be calculated using a
corrosion allowance and a manufacturers tolerance (see Chapter 3.5 of this
manual).
IP6

t min =

Pi D nom
+ t cor
2n h y

(3.1.1)

DnV

t nom =

(Pi - Po ) D
2n h y

nom

+ t cor

Penspen Andrew Palmers

(3.1.2)

PLUSONE WALL 5.2

Chapter 3 Theoretical Basis

ASME 31.4/ASME 31.8

(Pi

Po )
D nom + t cor
2n h y

t nom =

(3.1.3)

BS 8010
For this design code the following thin-wall formulae is used when the ratio of
Dnom : tmin is greater than 20.

t min =

(Pi

Po )
D nom + t cor
2n h y

(3.1.4)

The more accurate thick-wall equation is used when the ratio Dnom : tmin is less
than or equal to 20. In this case the positive root of the following quadratic
equation is used

t 2 t D nom +

2
D nom
nh y

2 1 +
Pi Po

=0

t min= t + t cor

(3.1.5)

(3.1.6)

where

tcor
tmin
tnom
Dnom
y
nh
Pi
Po

is
is
is
is
is
is
is
is

the
the
the
the
the
the
the
the

corrosion allowance
minimum wall thickness
nominal wall thickness
nominal outside diameter
specified minimum yield stress (SMYS)
usage factor or fraction of yield stress
internal design pressure
external design pressure

Penspen Andrew Palmers

PLUSONE WALL 5.2

Chapter 3 Theoretical Basis

The usage factor nh which is to be applied in the hoop stress formulae is specified
by the applicable design code and the zone or classification of the pipeline. For
submarine pipelines the code requirements governing design usage factors are
summarised in the following table:

Design Code

Usage Factor (nh)

Riser

Linepipe

Det norske Veritas, DnV '81

0.5*

0.72*

Institute of Petroleum, IP6

0.6

0.72

ANSI/ASME 31.4 & 49 CFR195

0.6

0.72

ANSI/ASME 31.8 & 49 CFR192

0.5#

0.72#

British Standard 8010, Part 3

0.6

0.72

TABLE 3.1. USAGE FACTORS FOR INTERNAL PRESSURE.

Notes:
*

DnV 1981 specifies the riser (zone 2) as the part of the pipeline less than
500m from any platform or building and the pipeline (zone 1) as the part
of the pipeline greater than 500m from any platform building.

ANSI/ASME 31.8 specifies the riser zone as the part of the pipeline which is
less than 5 pipe outside diameters from the platform and the pipeline zone
as the part of the pipeline which is more than 5 pipe diameters from the
platform.
3.2. Resistance To External Pressure

Failure due to external pressure or hydrostatic collapse is caused by elastic

instability of the pipe wall. For wall thickness determination the external pressure
is calculated from the hydrostatic head at extreme survival conditions. The
maximum water depth taking into account the maximum design wave height and
storm surge should be used. The minimum wall thickness required to prevent
hydrostatic collapse is determined from reference [1] for DnV, API 5L and IP6 and
from reference [10] for BS 8010.

Penspen Andrew Palmers

PLUSONE WALL 5.2

Chapter 3 Theoretical Basis

3.2.1. Timoshenko And Gere

In the first case the Timoshenko and Gere [1]formula is used to calculate the
minimum wall thickness as follows:

Po2 - 2 y

t min

D nom

D
1 + 0.03e nom
t min

Pc Po + 2 y

t min

D nom

Pc = 0

(3.2.1)

where

Po
Pc

is the external hydrostatic pressure

is the critical collapse pressure for perfectly circular pipe given by:

2E
Pc =
1 2

E
e
y

is
is
is
is

t min

D nom

(3.2.2)

Poisson's ratio
Young's modulus of elasticity
the eccentricity of the pipe (%) (see below).
the specified minimum yield stress (SMYS)

3.2.2. Murphy and Langner

BS 8010 advocates the use of the formula described in Murphy and Langner [10]
and this is described as follows:
Po

Pc

1 o

P y

1 = 2f o Po D nom

P t

y nom

(3.2.3)

where the notation is as above and in addition

t
Py = 2 y nom
D nom

fo

(3.2.4)

is the initial ovalisation, see below.

Penspen Andrew Palmers

PLUSONE WALL 5.2

Chapter 3 Theoretical Basis

3.3. Pipe Eccentricity, Out of Roundness and Initial Ovalisation

Pipe eccentricity is a measure of pipe out of roundness. This is generally a

specified manufacturing tolerance which is measured in a different way
depending on which code or standard is used. The various ways of measuring it
and permitted values are given as follows:

3.3.1. DnV
DnV uses the term out of roundness,
D
D min
2 max
x 100
D max + D min

(3.3.1)

This can be related to:

2x

D max D nom
x 100
D nom

(3.3.2)

2x

D nom D min
x 100
D nom

(3.3.3)

and

The above is not to exceed 2% either due to bending or from fabrication of the
pipe. (1% or 0.5% are specified as values prior to manufacture).

3.3.2. API 5L
API also uses the term out of roundness specified as follows:

D max D nom
x 100
D nom

(3.3.4)

D nom D min
x 100
D nom

(3.3.5)

and

API states that this should not exceed 1% prior to manufacture.

Penspen Andrew Palmers

PLUSONE WALL 5.2

Chapter 3 Theoretical Basis

3.3.3. IP6
IP6 uses the term eccentricity which is not defined specifically but can be
obtained from the original source of the equation stated in Appendix 7.

D max D nom
x 100
D nom

(3.3.6)

D nom D min
x 100
D nom

(3.3.7)

and

IP6 does not specify a maximum acceptable value but an eccentricity of 1% is

normally used.

3.3.4. BS 8010
BS 8010 uses the term initial ovalisation of the pipe cross section and defines this
in percentage terms as

D max D min
x 100
D max + D min

(3.3.8)

BS 8010 specifies that the initial ovalisation should not be taken as less than
2.5%.
The only calculation in the PLUSONE WALL module which uses out of roundness
is the external pressure (hydrostatic collapse) formula as given in IP6 and BS
8010.
The PLUSONE input screen value is referred to out of roundness as opposed to
eccentricity or initial ovalisation and is of the API format where:

IP6 % eccentrici ty = API % out of roundness

2 x API % out of roundness = DnV % out of roundness
BS 8010 % initial ovalisatio n = API % out of roundness

Penspen Andrew Palmers

PLUSONE WALL 5.2

10

Chapter 3 Theoretical Basis

The out of roundness tolerances with reference to API, DnV and BS 8010 is as
follows:

Code or standard

Out of roundness

IP6

1.0%

API

1.0%

DnV

1.0%

BS 8010

2.5%

3.4. Resistance To Propagating Buckle

The required buckle propagation wall thickness is the wall thickness below which
a buckle, if initiated, will propagate along the pipeline until a larger wall thickness
or a reduced external pressure is reached. The wall thickness required to resist
buckle propagation can be calculated from the following formula:
DnV:
Specified in DnV 1981 and DnV 1976, it is generally considered to be
conservative.

t nom =

k D nom
1+ k

k=

Po
1.15 y

(3.4.1)

Battelle:
Developed by Battelle Columbus Laboratories [4]

t nom

D
= nom
2

Po

6
y

0.4

(3.4.2)

Shell:
Developed by Shell Development Corporation [5]

t nom =

D nom
2

Po
y

Penspen Andrew Palmers

(3.4.3)

PLUSONE WALL 5.2

Chapter 3 Theoretical Basis

11

BS 8010:
Defined in BS 8010 Part 3 [9]

t nom = D nom

Po

10.7
y

4/ 9

(3.4.4)

A comparison of the results from each of the buckle propagation criteria is shown
overleaf in Figure 1. The selection of buckle propagation criteria depends on
individual company practice. Generally, however, the DnV formula is marginally
more conservative than the Shell Development Corporation formula and they are
both considerably more conservative than the Battelle formula. The degree of
conservatism required depends on the installation technique in terms of risk, the
length and cost of the line, and the water depth in terms of how easily a repair
can be made. In practical terms changing of any criteria will change the required
wall thickness.
However, since designers are normally limited to selecting from API pipe sizes,
there is quite often no actual change in the pipe specified.
If during design, a pipeline is found to be governed by buckle propagation criteria
then there are two options open to the designer. The first option is to make the
wall thickness of the pipe sufficient so that a buckle once initiated will not
propagate. The second option is to make the wall thickness of the pipe sufficient
to only withstand external pressure (hydrostatic collapse) and to use buckle
arresters. Buckle arresters consists of thick sections of pipe or welded fittings
which a buckle cannot propagate through. If buckle arresters are fitted, damage
will be limited to length of the pipeline between arresters should a buckle initiate.
This risk, however, is considerably reduced after installation. The choice between
the two is determined by considering the potential cost saving in wall thickness
and possibly installation benefits due to the reduced submerged weights. This is
paid off against the risk of having to replace a relatively large section of pipe
possibly in deep water. If the user wishes to examine the use of buckle arresters
he can set the buckle propagation option to 'none'. The module will then exclude
buckle propagation from the criteria analysed.

Penspen Andrew Palmers

PLUSONE WALL 5.2

12

Chapter 3 Theoretical Basis

WALL THICKNESS DETERMINATION

BUCKLE PROPAGATION CRITERIA
18
17
16

WALL THICKNESS (mm)

15
14
13
12
11
10
9
8
7
6
5
4
25

50

75

100

125

150

175

200

225

250

275

300

WATER DEPTH API 5LX60 (m)

! HYDROSTATIC

+ DnV

BATTELLE

" BS8010

SHELL

Figure 3.1 : COMPARISON OF THE REQUIRED WALL THICKNESS CALCULATED TO

RESIST BUCKLE PROPAGATION ACCORDING TO THE DNV, BATELLE, SHELL AND
BS8010 CRITERION

3.5. Maximum Diameter To Thickness Ratio

The pipeline wall thickness may be specified independently of the static design
criteria due to installation stress limits. Determination of the installation stresses
is beyond the scope of the wall thickness module and is addressed during lay
stress analysis or J-tube pull-in analysis. If the pipeline is to be installed by the
reel method, a maximum diameter to thickness ratio is recommended to avoid
excessive out of roundness of the line during reeling. The ratio will depend upon
the line size, reel diameter and total length of line to be reeled. As a general
guideline, a diameter to thickness ratio of less than twenty three (23) is used for
reel barge installation.

Penspen Andrew Palmers

PLUSONE WALL 5.2

Chapter 3 Theoretical Basis

13

3.6. Nominal Wall Thickness

The nominal pipe wall thickness of linepipe is the specified wall thickness taking
into account manufacturing tolerance.

3.6.1. Corrosion Allowance

The external surface of submarine pipelines is generally protected from corrosion
with a combination of external coating and a cathodic protection system. The
internal surface, depending upon the service, may be subject to corrosion. This is
accounted for by the addition of corrosion inhibitors or applying a corrosion
allowance to the pipeline wall thickness. The corrosion allowance is calculated
from the anticipated corrosion rate and the design life of the pipeline system.

3.6.2. Manufacturing Tolerance

Manufacturing or mill tolerances are specified acceptance limits for the linepipe
wall thickness during manufacture. The tolerance will depend upon the size of
pipe and manufacturing process involved. A negative wall thickness tolerance
should be taken into account when calculating wall thickness required for hoop
stress criteria. The specified nominal wall thickness is calculated from the
minimum required wall thickness as follows:

t nom = t min x

100
100 t tol

(3.6.1)

ttol = negative manufacturing tolerance as specified by codes DnV, IP6 etc.

3.7. Test Pressure
The BS 8010 design code [9] gives criteria to calculate the minimum hydrostatic
test pressure for a pipeline.
The test pressure required to qualify for a MAOP (Maximum Allowable Operating
Pressure) equal to the specified design pressure is the lower pressure of the
following:
a)

150% of the internal design pressure.

b)

the pressure that will result in a hoop stress (based on specified

minimum wall thickness) equal to 90% of the specified minimum
yield stress.

Penspen Andrew Palmers

PLUSONE WALL 5.2

14

Chapter 3 Theoretical Basis

The test pressure should be referenced to the Lowest Astronomical Tide (LAT)
and due allowance made for the elevation of the pressure measurement point
and parts of the system above LAT.

Penspen Andrew Palmers

PLUSONE WALL 5.2

Chapter 4 API Standard Wall Thicknesses

4.

15

API Standard Wall Thicknesses

The American Petroleum Institute (API) specification for line pipe is based upon a
range of standard diameters and wall thicknesses. These values are different for
both imperial and metric sizes. Pipe mill tooling and production is set up around
this specification. Non-standard line sizes are sometimes used, for risers where a
constant internal diameter is specified, or for alloy steels which are manufactured
to special order and sized to meet production requirements.
The WALL module determines the required wall thickness for each of the design
criteria, the largest (governing) is then used to select the suitable standard API
wall thickness for that line size, based on either metric or imperial API 5L
standard pipe sizes.

Penspen Andrew Palmers

PLUSONE WALL 5.2

16

5.

Chapter 5 Module Operation

Module Operation

The output from the module is in terms of the required wall thickness for each of
the criteria considered. From these, the governing wall thickness is selected and
compared with the nearest available pipe size. A list of all the other available API
pipe sizes for the particular diameter is also included in the output.

Penspen Andrew Palmers

PLUSONE WALL 5.2

Chapter 6 External Data File

6.

17

External Data File

The WALL module uses an external data file to obtain information on usage
factors for pipes and risers which vary depending on each code selected. The
safety factor used with the external pressure is also contained in this file.
This file is called FIL1.DAT and is located in the PLUSONE directory. It is held
in ASCII format, which can be edited using most of the popular editors such as
Word Perfect or Microsoft Word. An ASCII editor is also supplied with
PLUSONE.
WARNING You should only edit this file if you have a good reason to do so, for
example to change the hydrostatic collapse safety factor.
6.1. Data File structure
Line 1

Description of the file's data format

Line 2+

These lines have 6 fields, each as follows:

Field 1 - Code, eg DnV, IP6, ASME, BS 8010 etc
Field 2 - Pipe usage comment, purely descriptive
Field 3 - Pipe usage factor
Field 4 - Riser usage comment, purely descriptive
Field 5 - Riser usage factor
Field 6 - Hydrostatic safety factor

The file is a 'comma delimited file', i.e. each field has a comma to separate it from
the next piece of data. The standard version of the file is shown below:
6.2. Example structure as supplied
Code,PipeUsage,Comment,RiserUsage,Comment,Hydrostatic safety factor
DnV,(Zone 1 > 500m),.72,(Zone 2 < 500m),.5,2
IP6,,.72,,.6,2
ANSI31.8,(Class A > 5 x OD),.72,(Class C < 5 x OD),.5,1
ANSI31.4,,.72,,.6,1
BS8010,,.72,,.6,1

Penspen Andrew Palmers

PLUSONE WALL 5.2

18

Chapter 6 External Data File

6.3. Customising the data in FIL1.DAT

To edit this file, you can use any ASCII editor, however we recommend using
P1ED.EXE, located in the PLUSONE directory (see the PLUSONE System
Manual). The editor itself is designed to be straightforward in use, and once the
changes have been made, you can save the file and exit back to DOS.

Penspen Andrew Palmers

PLUSONE WALL 5.2

Chapter 7 References

7.

19

References
1.

Theory of Elastic Stability, Timoshenko and Gere, 2nd Edition, 1961,

published by McGraw-Hill.

2.

DnV - Rules for Submarine Pipeline Systems, Det norske Veritas, Hvik,
Norway (1981).

3.

DnV - Rules for Submarine Pipeline Systems, Det norske Veritas, Hvik,
Norway (1976).

4.

Johns, T.G., Meshlokh, R.E. and Sorenson, J.E. 'Propagating Buckle

Arrestors for Offshore Pipelines', OTC 2680, Offshore Technology
Conference (1976).

5.

Langner, C.G. 'Arrest of Propagating Collapse Failures in Offshore

Pipelines', Shell Deepwater Pipeline Feasibility Study (1975).

6.

IP6 - Institute of Petroleum Pipeline Safety Code (UK code).

7.

ASME 31.8 - American Society of Mechanical Engineers, Liquid

Transportation Systems for Hydrocarbons, Liquid Petroleum Gas,
Anhydrous Ammonia, and Alcohols.

8.

ASME 31.4 - American Society of Mechanical Engineers, Gas Transmission

and Distribution Piping Systems.

9.

BS 8010 - Code of Practice for Pipelines. Part 3. Pipelines subsea: design,

construction and installation (1993).

10. Murphy C.E. and Langner C.G. 'Ultimate Pipe Strength under Bending,
Collapse and Fatigue', (1985).

Penspen Andrew Palmers

PLUSONE WALL 5.2