DNV Pipeline Coupling PDF

RECOMMENDED PRACTICE
RP-F104
MECHANICAL PIPELINE COUPLINGS

1999
DET NORSKE VERITAS

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FOREWORD
DET NORSKE VERITAS (DNV) is an autonomous and independent Foundation with the objectives of safeguarding life,
property and the environment, at sea and onshore. DNV undertakes classification, certification, and other verification and
consultancy services relating to quality of ships, offshore units and installations, and onshore industries world-wide, and
carries out research in relation to these functions.
DNV publishes various documents related to the offshore industry, aimed at promoting quality and safety on offshore units and
installations.
The Recommended Practice publications (RP-series) cover proven technology and solutions which have been found by DNV
to represent good practice, and which represent one alternative for satisfying the requirements stipulated in the DNV Offshore
Standards or other codes and standards cited by DNV. The DNV RP-series is divided into 6 parts, as follows.
A)
B)
C)
D)
E)
F)
Quality and Safety Methodology

Materials Technology
Structures
Systems
Special Facilities
Pipelines & Risers
As well as forming the technical basis for DNV verification services, the Offshore Standards and Recommended Practices are
offered as DNVs interpretation of safe engineering practice for general use by the offshore industry.
ACKNOWLEDGEMENTS
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CONTENTS
1.
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
2.
2.1
2.2
3.
3.1
3.2
4.
4.1
4.2
4.3
4.4
5.
5.1
5.2
5.3
5.4
5.5
General..................................................................... 4
Introduction ............................................................... 4
Application................................................................ 4
Structure of Recommended Practice ......................... 4
Coupling categories................................................... 4
Coupling grouping .................................................... 4
Specifications ............................................................ 5
References ................................................................. 5
Definitions................................................................. 5
Symbols..................................................................... 5
Basic philosophy ...................................................... 6
Qualification.............................................................. 6
Analytical methods.................................................... 6
Pipeline Design Basis............................................... 7
General ...................................................................... 7
Dimensional Tolerances............................................ 7
Pipeline forces.......................................................... 8
Fundamental forces ................................................... 8
Maximum Axial Forces............................................. 8
Force boundaries ..................................................... 10
Limiting displacements ........................................... 10
Installation ............................................................. 11
General .................................................................... 11
Entry........................................................................ 11
First end entry control ............................................. 12
Seal protection design ............................................. 12
Water block ............................................................. 12
5.6
Second end entry ..................................................... 13
5.7
Misalignment limitations ......................................... 13
5.8
Activation ................................................................ 13
5.9
Seal test.................................................................... 13
5.10 Monitoring and control ............................................ 14
6.
Design...................................................................... 15
6.1
General .................................................................... 15
6.2
Material properties................................................... 15
6.3
Strength capacity ..................................................... 15
6.4
Seal capacity............................................................ 16
7.
Testing .................................................................... 17
7.1
Test philosophy........................................................ 17
8.
Documentation ....................................................... 18
8.1
Documentation......................................................... 18
8.2
Qualification check list ............................................ 18
8.3
Quality assurance..................................................... 18
8.4
Traceability.............................................................. 18
Appendix A Coupling Capacity ..................................... 19
A.1
Coupling Strength Capacity..................................... 19
A.2
Seal Capacity ........................................................... 22
Appendix B Typical tests................................................ 24
B.1
Basic tests ................................................................ 24
B.2
Type tests................................................................. 25
B.3
Factory acceptance tests .......................................... 28
B.4
Installation verification tests.................................... 29
Appendix C Check List for Qualification ..................... 30
DET NORSKE VERITAS
Recommended Practice RP-F104

September 1999
Design (Sec. 6) deals with main principles in design. Further
guidance/discussions are given in Appendix A
1. General
1.1 Introduction
This Recommended Practice applies to couplings or sleeve
type couplings for pipelines.
Couplings are mechanical connectors which join the pipes by
direct attachment to the pipe wall. Couplings are different
from flange connectors, which join pipes by aid of additional
thick, machined pieces of material (the flange) welded or
forged to the pipe ends prior to pipe installation.
Couplings require no welding of the pipe and the pipe ends
can be:
Testing (Sec. 7) deals with the test philosophy relevant for

the various development phases. Typical tests are
described in Appendix B
Documentation (Sec. 8) deals with documentation
requirements and certification relevant for the various
development phases.
The specifications given in this Recommended Practice are
supported by guidance, which is shown by Guidance notes.
1.4 Coupling categories
1) Joined subsea or above sea;

2) Joined beyond diving depth where welding is not
qualified;
3) Tied in to platforms or subsea installations.
1.4.1 Strength
equal or greater than that of the pipeline, or
The pipe itself represents the key internal component of a

coupling and hence can also present limitations due to: e.g.
pipe wall strength, surface irregularities and circular/straight
shape deviations. Furthermore, the coupling must be
installed with caution to reduce the likelihood for e.g. seal
damage.
reduced compared to that of the pipeline
The pressure containing capacity and the bending strength of

the coupling shall at least be equal to that of the pipe, but the
tension and torque strength need not necessarily meet this
criteria.
1.
1.2 Application
This Recommended Practice is intended to provide criteria
and guidelines for the qualification of mechanical pipeline
couplings. This includes important aspects relating to
coupling design, manufacture, safe installation and operation.
The Recommended Practice applies generally, but
particularly to subsea installations, and is intended to be used
as a supplement to the DNV OS-F101.
The axial and torsion strength capacity of the coupling can

either be:
1.4.2 Installation Sensitivity

Two categories of installation sensitivity apply to couplings
as follows:
2.
The sensitive type: No touch between pipe and seal is

allowed prior to activation
The less sensitive type: Limited interaction forces with
the seal are allowed.
1.5 Coupling grouping

Common locking principles showing a cross-section of the
pipe wall and the coupling sleeve are illustrated in
Figure 1-1.
Pipe wall
Coupling
Friction
1.3 Structure of Recommended Practice
Grip
This document consists of the following main elements:

General (Sec. 1)gives general information on couplings, their
application, relationship of this document to the DNV
offshore standards, and the classification of couplings
with respect to strength and sealing.
Forged
Balls/Forged
Basic philosophy (Sec. 2) establishes the basic principles for

qualification of couplings. A system for following up
issues of concern for the qualification is tabulated in
Appendix C
Pipeline (Sec .3), Pipeline forces (Sec.4) and Installation
(Sec.5) deals with the main input parameters for coupling
design
Flanged
Machined
Figure 1-1 Locking principles
DET NORSKE VERITAS
September 1999
The locking principles can be divided into two main groups:
1.9 Symbols
1) Uniform attachment between the pipe-wall and sleeve,

such as caused by a range of local attachments and or
friction.
2) Spot attachment such as caused by one or a few
circumferential attachments.
Where used in this document, the following symbols are

defined as:
Furthermore, the main coupling attachment methods are

based on the following two principles:
1) External compression of pipe compression couplings
2) Internal expansion of pipe expansion couplings
There are two main force responses of the locking principles.
These are:
1) Based on initial pre-compression
2) Improved by pipe tension due to wedging effects
The main sealing principles are:
1) Metal ribs or corners of grooves in the sleeve
2) Pre-compressed Polymer seals or Flexibel Graphite seal
enclosed by anti extrusion rings
3) Pre-compressed Polymer seals strengthened by metals or
fibres.
1.6 Specifications
The specification for a pipeline coupling shall include a list
of all limiting parameters and relevant parameter
combinations for installation and operation. Furthermore, it
shall describe the minimum requirements (main
specifications) for tools which are required to enable
coupling installation within safe limits.
1.7 References
DNV Offshore Standard OS-F101: Submarine Pipeline

Systems, is the update of: DNV Rules for Submarine
Pipeline Systems, 1996, referred to in this document as:
DNV OS-F101
API Bul 63 Testing of Oilfield Elastomers
API spec GH Specification on End Closures, connectors
and swiches.
Ae
Ai
As
D
E
et
fy
=
=
=
=
=
=
=
Locking
mechanical firm connection
Locking
capacity
mechanical strength of the coupling and

pipe joint
Safety factor
see Sec. 2.1 item 4
Sleevetype
coupling
coupling enclosing the pipe as a sleeve.

This applies to all current pipeline
couplings.
Pipe steel cross sectional area D t t 2
Outside pipe diameter

Modulus of elasticity
External diameter tolerance
Yield strength to be used in pipeline design
according to DNV OS-F101
SMYST u
Gravity force of pipe with internal fluid and
possible concrete per unit length, i.e. combined
weight and buoyancy.
Pipe wall axial force, i.e. the axial force as
imposed on the coupling (Tension is positive)
N/(As*fy)
Notations used for N:

=
Pressure test (Npt)
pt
=
Operation
o
Restrained pipe case, either in compression or
=
b
tension
=
Pipe moving cases
c
1, 2, 3 and 4 are related to: expansion forces
=
Numbers
due to: 1) pressurised and hot, 2)
depressurised and hot, and contraction forces
due to: 3) pressurised and cold, 4)
depressurised and cold.
pi
=
Internal pressure
pe
=
External pressure
=
pi,operation-pi,installation
pi
R
S
=
=
S
SMYS
=
=
SMYST
=
=
T
t
1.8 Definitions
D2
4
Internal pipe cross section area (D 2 t )2
4
External pipe cross section area
=
=
=
=
=
Other definitions are given where relevant in the text.
DET NORSKE VERITAS
Average bending radius

Effective axial pipeline force, i.e. forces
transferred by soil friction, supports etc.
(Tension is positive)
S/(As*fy)
Minimum specified yield strength of the
pipe material
SMYS de-rated due to elevated temperature
Temperature-difference
Wall thickness
Temperature-expansion coefficient,
material strength factor according to DNV
OS-F101 0,96 for normal materials 1,00
for materials to supplementary
requirements U
Poissons ratio
Lateral Coulomb friction factor simulating
lateral soil resistance

September 1999
2. Basic philosophy
2.2 Analytical methods
2.1 Qualification
2.2.1 General
The qualification of couplings should, in general, be based

on verification of compliance with given functional
specifications and safety margin against possible failure
modes.
This qualification should be based on the following
principles:
1) Functional requirements shall be quantitative.
2) Possible failure modes shall be identified (See Sec. 6.1).
3) Theoretical analysis/calculations shall be used as the
main tool to document fulfilment of the functional
specifications and safety against failures. The theoretical
calculations shall be verified by tests.
4) The safety factors shall be established based either on
recognised standards, or on combinations of all
uncertainties and inaccuracies used in the data,
operation, calculations and tests. This applies to loads,
strength, sealing and function. (Acceptable failure
probabilities versus Safety Class is defined in DNV
OS-F101. The Safety Class high applies for general
use because it covers all classes.)
5) Measurements and tests shall be used as the main tools
to document that manufacturing gives fulfilment of the
functional specifications.
6) A systematic approach shall be applied to ensure that all
functional specifications are fulfilled for new
concepts/applications. This shall be based on a
combination of an analytical/numerical approach and
prototype tests.
7) Experience which is intended to be used as proof of
fulfilment of the specifications and safety against
possible failures modes shall be documented.
8) Tests or reference to recognised literature shall identify
limiting material and functional parameters.
9) Alternative methods to those described in this document
may be used provided that they are supported by
equivalent evidence for the suitability of their
application.
An analytical/numerical approach should be applied as the

main tool to enable qualification. This type of approach will
establish the individual and combined effects of the different
parameters.
Guidance note:
Finite Element Analysis (FEA) may be used for detailed study of
stresses and deflections from symmetric and unsymmetrical
loads, including material plastic yield, friction, contact, collapse
and motions, i.e. combination of a range of non-linear effects.
A theoretical model including all parameters and effects will be
complex to use, and so it is often more practical to apply simpler
models for analysis of separate parameter effects. Such models
can also be studied by FEA, and/or by simplified analysis.
Programs such as mathematical programmes or spreadsheets
are the most convenient for handling simplified analysis. The
advantage of using a mathematical programme rather than a
spreadsheet is that the method (formulas) is easily documented.
Spreadsheets are widely used, but require additional
documentation of formulas which are actively used in the
computations.
Simplified Analysis may be used when the behavior is
understood and the computation model is representative. But it
maby be difficult to apply when all relevant effects are combined
and may also have larger inaccuracies than complex FEA.
Elastic - formulas
Formulas can be developed either by derivation from textbooks
or based on test results. Software with formulas from some
textbooks such as Roarks formulas for stress and strain is
available. These formulas are limited to elastic analysis.
Plastic - formulas
Formulas for plastic yield can be developed, but normally require
calibration by test and/or FEA. Practical applications would be to
establish possible plasticity of the pipe shell, both through the
wall and by hard bodies (seals and grips) forced into the surface.
DET NORSKE VERITAS
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September 1999
3.2.3 As installed
3. Pipeline Design Basis

3.1 General
The installation procedures can, in particular cases, cause

additional flattening (out of roundness) due to bending of the
pipe.
The pipeline design basis shall be specified, and shall

include:
3.2.4 Extreme Maximum & Minimum diameter
Design pressure, fluid temperature and description of

transported fluid,
Water depth and sea temperature,
External pipe diameter, wall thickness, corrosion
allowance and material specification,
Reference standard for manufacturing and dimensional
tolerances.
Guidance note:
The pipeline standards specify most of these tolerances related to
pipe fabrication and pipeline installation. Dimensional tolerances
of concern to coupling design are dealt with in the following.
The maximum and minimum internal no touch coupling

diameter to cover the tolerance combination em, which is due
to each of the above extreme tolerances excluding the
possible flattening effects from the installation, is:
em = et 0.5eo el +es
Provided the installation effects (above subsection) can be
neglected, this represents a conservative extreme limit. A
less extreme and more realistic limit can be based on
procedures described in the next subsection.
Guidance note:
The effects of the straightness es should also be dealt with
separately for assessing the alignment during installation (see
Sec. 5).
3.2 Dimensional Tolerances
3.2.1 Welds and surface imperfections

The weld itself can cause a local discontinuity on the pipe
surface. Surface roughness and discontinuity tolerances are
of concern with respect to the seals. The coupling shall be
qualified for the pipe either:
with the quantified surface imperfection

or
after removal of the surface imperfection.
3.2.5 Statistical Maximum & Minimum diameter

Guidance note:
The extreme tolerance combination is unlikely to occure for most
pipeline types.
The design of sleeve type couplings is sensitive to the pipeline
dimensional tolerance. Specification of an over conservative
tolerance combination could be difficult to cover with one size of
coupling.
3.2.2 Line pipe
External diameter tolerance, et is mainly derived from the

measurement of the circumference and therefore represents
an average.
Statistical evidence shall be used to establish the likely

maximum tolerances, if not the unlikely extreme tolerance
combinations presented in the subsection above is applied.
Out of roundness (OOR, ovality) tolerance, eo is measured by

a gauge.
Local out of roundness tolerance, el, reflects dents and
peaking.
Straightness of the pipe section, is normally measured by a
taut string between the ends, and measures the greatest
distance to the pipe surface. Straightness within the length of
a coupling is normally not specified and therefore special
considerations must be made.
Straightness of the pipe section of concern es is within the
length of the coupling. The following formula applies to a
possible S shaped pipe:
es = (2l/L)2sL/100
l
Length of coupling for l/L<0.5
Length of line pipe section (normally 12m.) or

specified section
Straightness of pipe/section specified in % of L
DET NORSKE VERITAS

September 1999
4. Pipeline forces
4.1 Fundamental forces
Tension and torque forces in the pipeline are removed when
by cutting the pipeline subsea.
The changed pipeline conditions after coupling installation
generate the following forces:
1) Soil friction. This force is dependent on the friction
coefficient and the force/displacements caused by:
Axial expansion forces due to increased

temperature;
Axial expansion due to changed pressure; or
Subsidence of the sea bottom resulting in lateral
displacements e.g. as in the Ekofisk area in the
North Sea.
2) Pressure forces acting on the pipe internal cross section,

the End cap effect.
3) Forces caused by the repair operation and gravity, such
as tension/compression, bending moment and torque.
4) Forces released after the repair operation, such as
tension forces in steep slopes
5) Possible changes in pipeline support/soil conditions e.g.
causing free spans.
6) Possible external transverse loads from fishing gear.
7) Possible hydrodynamic forces caused by current and
wave actions.
8) Accidental loads identified to be of concern e.g. caused
by mud slides and dragging anchors
Guidance note:
It is expected that sleeve type couplings will at least have the
same capacity for resistance of internal pressure and bending
moments as that of the pipeline. Compressive loads will normally
be supported in recesses inside the coupling or by the pipe ends
meeting each other. Torque can be caused by the connecting
operation when curved spool pieces are used. Normally of most
concern will then be tension in operation.
Item 1 is only of concern to pipelines with elevated

temperatures and for some soil conditions.
Item 2 is also predictable and can be controlled by
inspection.
Item 3 is only seldom of concern.
Item 4 is easily predictable based on the joining tool
capacity.
4.2 Maximum Axial Forces

4.2.1 Scenarios
The maximum tensile forces to which the coupling could be
exposed during normal operation, depend on.
Pipeline soil interactions,

Operating conditions.
The following three scenarios represent the limiting

conditions:
a)
Free pipeline, elbow or free end of pipeline, all with

internal over-pressure. The axial pipeline end cap
force is governed by the pressure and hence the test
pressure force dominates.
b) Restrained pipeline. The axial pipeline force is governed
by rigidity of the restraint.
c) Pipeline on seabed with expansion loops or
imperfections. The force is less than half the force
determined for an imaginary completely fixed pipeline,
provided that the possibility of locking of the pipe (e.g.
by sand settling) in an expanded (e.g. by temperature
and pressure) configuration is avoided.
4.2.2 Free pipe end end cap, (scenario a)
This load case is typically related to the conditions during
factory pressure test and installations in expansion loops with
negligible friction. The normalised force relative to the pipe
yield strength is:
A load condition of concern to a sleeve type coupling is

tension, with no internal pressure. This is a rare case which
can occur if;
1) the pipeline, in a hot condition, changes position due to
the temperature expansion (snaking), and thereafter the
fluid transport is stopped. The pipeline then cools off
and the pressure is relieved;
2) a free span is developed underneath the coupling and the
adjacent pipeline, either in an expansion loop or on a
large slope;
3) the pipeline is subject to subsidence, mud slides or
dragging anchors; or
4) the connection operation applies large external forces to
join the two pipe ends.
N '=
p i Ai p e A e
f y As
(1)
This maximum axial tensile force will be established as:
Npt
No at design pressure.
during pressure test
Guidance note:
The maximum internal seal diameter in the coupling governs the
the internal pressure term of the axial force.
DET NORSKE VERITAS
September 1999
4.2.3 Restrained pipeline, (scenario b)
4.2.4 Expansion loop effects, scenario c)
Compression (Initially restrained pipe)

The maximum obtainable compression forces through the
coupling occur if the pipeline at each side of the coupling has
been rock dumped before pressurisation. This restricts
coupling expansion completely, giving a force relative to the
pipe strength of:
pi Ai
E T pi Ai pe A e
(1 2 )
+
f y As
fy
f y As
This is illustrated by Figure 4-1which shows the effects of

lateral soil resistance on axial force.
(2)
Effective Force
N 'F =
The axial forces are within the limits identified by scenario

a) and b). An expansion loop or a pipeline with an initial
imperfection may respond to the axial force by deflections of
the pipeline curvature, governed by the resistance to this
deflection.
This condition is considered conservative. At elevated

temperatures, the adopted design configuration may allow
the pipe to buckle.
SF= Limit due to

available force
Pipe/Curvature
Expansion
High temperature is of concern for export pipelines close to

platforms, and flowlines close to wells. The tie-in
arrangement normally allows for axial pipeline expansion
and therefore this force will be smaller than above in most
cases.
soil penetration beneath an upheaval buckle;

soil cover on expansion the loop, restricting movement
back to the original position; or
the pipeline has been rockdumped whilst in operation.
Equation (2) also applies for the tension force provided that
the following definitions are made:
p i
T
Internal pressure after shut down (pressure at

installation) minus internal pressure before.
Temperature after shut down minus temperature
before.
Note that the signs will be changed for the two first terms of
equation (2):
With pressure and cooled down

Nc 4
E T
fy
pi Ai
2 As f y
pi Ai pe Ae
f y As
pi Ai pe Ae
( 1 2
f y As
Sf1
Reduced lateral
soil resistance
SF
Figure 4-1 The effective force S in the restrained pipe

as function of the pipe expansion in the curvature. This
expansion is limited by the lateral soil resistance.
Guidance note:
This figure represents an ideal case which considers:
equal lateral friction coefficients for expanding and

contracting motions, and
pipeline curvature radius, which is not affected by the
motion.
The maximum pipe tension and maximum positive effective

force, can only be obtained when:
The friction coefficient, curvature radius and weight are all
relatively high.
At start-up of the pipeline, the friction will first cause
compressive forces in the pipeline until the friction resistance
capacity is exceeded. The pipeline will then start to move
laterally.
The lateral resistance corresponds to an axial capacity of Sf1, Sf2
or Sf3.
After pressure relief & cooled down, assuming an internal

pressure reduction until there are no end cap effect
(scenario a)
Nc 4
(Compresive)
The shutdown includes pressure release and cooling. Given

that the pipeline is initially free to expand longitudinally
without any resistance in order to accommodate temperature
and pressure effects, then subsequent restraint can be caused
by, e.g.
Sf2
(Initially free, then restrained pipe)
Tension
Sf3
)+
E T
2 fy
The remaining part of SF causes the motion by Pipe/curvalure

Expansion as shown by the figure. This expansion continues
until the compressive force is reduced to a level which is equal to
the soil capacity for the curved pipe. Thereby this compressive
force remains in the pipe when it stops.
When the pipeline is shut down, and thereby cools down and depressurises, it will contract, i.e. be offloaded and subject to
tension due to the soil interaction. This remaining tensile force:
will be limited by the soil friction capacity,

cannot be larger in magnitude than the compressive force,
is created after the initial compressive force is released.
DET NORSKE VERITAS
10

September 1999
These limits are indicated on the upper part of the figure by the
two 45 lines. Possible tension Effective Force is below these
limits.
Guidance note:
Typical soil resistance coefficients are given in Table 4-1:
Therefore the maximum tension force is limited to half the

possible restrained Effective Force when the end cap force is
neglected.
Table 4-1 Typical pipe/soil friction coefficients
The maximum pipe relative tension force in the expansion

loop, when conditions enabling scenario b) can be neglected,
is:
Soil type
Axial
Lateral
Sand
0.5 to 0.6
0.6 to 1.0
Clay
0.2 to 0.5
0.2 to 1.0
4.3 Force boundaries

N 'c 4
pi Ai
2 As f y
(1 2 ) +
E T
2 fy
pi Ai pe Ae
f y As
(3)
With pressure and cooled down

N 'c 4
The maximum residual tensile stress given by the previous

three scenarios are plotted in Figure 4-3, and are for a
pipeline with main design parameters:
E T pi Ai pe Ae
+
f y As
2 f y
After pressure relief and cool down assuming an internal

pressure reduction until there are no end cap effect
(scenario a):
Material:
Steel
Usage factor for pressure containment: (Safety Class
High) s = 0.8 and (Pressure test) s = 0.96 according to
DNV OS-F101
D/t = 27,9
pe = installation pressure
No end cap effects after depressurization
1.40
2 As f y
(1 2 ) +
E T
scenario b, pressure
2 f y
Figure 4-2 shows the actual pipe forces in an expansion loop

configuration.
Pipe line with imperfection
Axial Stress/SMYS
N 'c 4
pi Ai
1.20
scenario b, no pressure
1.00
scenario c, no pressure
scenario c, pressure
0.80
scenario a, pressure test
0.60
0.40
0.20
Part of pipeline in the

imperfection illustrating
the equlibrium
between axial effective
force and friction
capacity
0.00
40
60
80
100
120
140
160
Differential Temperature
Figure 4-3 Maximum tensile forces in a pipeline for the

three scenarios described
S
m
4.4 Limiting displacements
The cutting of a pipeline with maximum internal tensile

stress implies that the effective force in the pipeline is
released and reduced to zero.
Figure 4-2 Simplified calculation of required pullback

forces
During a pipeline contraction, the maximum tension force
relative to the pipe strength is:
N 'c =
20
R m p i Ai p e Ae
+
f y As
f y As
(4)
The following general calculation can be modified. S0 is the

maximum tension force and s is the axial friction
coefficient between the pipe and the sea bottom (N/m):
The axial displacement l of the pipe end is:
l =
S
1
0
2
E ( D t t ) 2 s
The lateral soil resistance (friction) coefficient is

dependent on the weight of the pipe, soil type, character of
motion and length of motion. Complex methods are available
to predict such coefficients.
DET NORSKE VERITAS
(5)
11
September 1999
Direction of movement
5. Installation
5.1 General
The limiting installation conditions shall be specified and
calculated.
< max misalignment
Guidance note:
These conditions are in particular related to item 6, 7, 8 and 9 of
the following operations:
1)
2)
Seabed preparations to enable carrying of heavy frames.

Installation of pipe end manipulating devices (H frames) if
required.
3) Cutting and removal of pipe ends.
4) Coating removal and preparations of pipe ends.
5) Manipulation and aligning of pipe ends or excavations.
6) Subsea measurements and surface adjustments of possible
intermediate pipe section and the coupling.
7) Deployment of coupling, its installation tool and the
intermediate pipe section.
8) Installation and activation of the coupling.
9) Testing of seals.
10) Pressure testing of pipeline, if required.
11) Deployment of the joined pipe to the sea-floor from the
lifting frames, if used.
12) Seabed preparations/protection.
Indicates contact between pipeline and coupling
Case 2 - Entry on pipe end 1. The misalignment is larger

than the maximum misalignment for the coupling based on
clearance to the pipe. Final entry is obtained by angular and
radial compliance of the couplings suspension system. The
risk of jamming is to be considered.
> max misalignment
The pipe ends shall be prepared for the coupling installation.

Couplings are fitted to the external parts of the pipe and normally
require removal of the pipe coating. Most couplings also require
a certain evenness of the pipe end and surface. Therefore subsea
chamfering, grinding or machining can be required.
Installation of the coupling on to the pipe ends may require strict
control to avoid damage to seals. Therefore special tools may be
required to control the coupling installation, as well as for
coupling activation and testing.
In most cases, it will be practical to join the pipeline ends using a
spool piece (intermediate pipe section).
After aligning the pipe ends, the coupling is moved to the correct
position and activated.
Case 3 - Misalignment is less than maximum possible

misalignment for the coupling (based on clearance between
pipe and coupling). Entry on pipe end 2, when pipes are
misaligned and offset relative to each other. Both pipe ends
are held in position by the installation system. Angular and
radial motion of the coupling is governed by the rigidity of
its suspension system. The pipeline is held in position by
the installation system.
---e-n-d---o-f---G-u-i-d-a-n-c-e---n-o-t-e--Direction of movement
5.2 Entry
The limiting parameters related to the following cases shall
be established, and shall include:
< max misalignment
misalignment angles and offset;

limiting bending moments, contact forces allowed
during installation, and related friction forces to
overcome during installation.
Such entry cases shall include the following:
< max misalignment
Case 1 - Entry on pipe end 1. The angular and radial motion

of the coupling is normally governed by the rigidity of its
suspension system. The pipeline is held in position by the
installation system. Misalignment is less than maximum
possible misalignment for the coupling (based on clearance
between pipe and coupling). Final entry is obtained by
radial compliance of the couplings suspension system.
Case 4 - Entry on pipe end 2, as case 3, but the alignment

tolerances, as governed by clearances, are exceeded. The
flexibility of the pipe suspension system including the pipes
themselves must be considered.
DET NORSKE VERITAS
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September 1999
Dc
> max misalignment

Pipe
x
Seal
Coupling
n
> max misalignment
yi
Figure 5-1 Misalignment and eccentricity

Guidance note:
The shape of the coupling can be used to guide the installation
e.g. with a funnel to guide entry during the initial installation.
5.3 First end entry control
A practical method for control of the interaction forces, is

obtained by compliant radial support of the coupling during the
installation.
Two categories of installation sensitivity are defined:

1) The sensitive type: No touch between pipe and coupling
allowed prior to activation
2) The less sensitive type: Limited interaction forces are
allowed.
Category 1 requires a strict control of geometric installation
parameters, and therefore an accurate monitoring and control
system. The limiting combination of in-plane eccentricity x
and misalignment angle a (see Figure 5-1) are represented
by (Case 1):
e/2 > x1 + ay1
5.4 Seal protection design

The seal is the most sensitive part of a coupling, and hence
no interaction with the pipe prior to activation is preferable,
i.e. the above category 1. However, the seal design must
compensate for less accurate installation systems. This may
for example be obtained by use of a sealing system which is
retracted from the inner circumference of the coupling. This
system requires an increase of the inner radius of the seal
relative to that of the coupling of at least:
where:
e(yi-n)/n+s
Dc
D
x1
a
y1
=
=
=
=
=
diametric clearance (considering constant

internal diameter): Dc-D
Coupling bore diameter
Pipe external diameter including tolerances
eccentricity (offset from centre line) at entrance
Misalignment angle (radians)
Overlap length i.e. degree of sleeve
displacement over the pipe(s) at the moment of
time considered. Maximum y1 is the length of
the coupling.
For installation systems with active control to give the

optimum position of the actual offset from centre at entrance,
the limit is (Case 2):
where:
n =
yi
s
=
=
axial length from the coupling entrance to the end

of the same inner diameter. (Length of equal
internal diameter)
Distance from the coupling entrance to the seal.
Safety distance (say 0.3 mm) to compensate for
deflections and possible protrusions on the pipe
end.
Furthermore, this system requires that the seals remain

concentric in the coupling until activation, and that no axial
internal friction force inside the coupling can activate the
seals.
5.5 Water block
e > a y1
These limits also apply to Category 2 couplings, but the
degree of control and monitoring can be relaxed.
Water trapped in cavities which are to become sealed off by

the installation can resist further displacements and shall be
avoided, unless proven to have no such adverse effects.
Guidance note:
This is of particular concern to designs with several main seals in
series.
DET NORSKE VERITAS
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September 1999
5.6 Second end entry

Installation of a coupling onto the second pipe end requires
careful alignment of the pipes. For plane misalignment of
Category 1 couplings with position control during
installation (Case 4), then:
e >( by2+x2)/2 when by2 > x2
Otherwise
The pipe stresses, deflections and safety against collapse

during the activation shall be established.
5.9 Seal test

The coupling shall be designed to allow for a seal test
without requiring pressurisation of the pipeline.
e > x2
where:
b
=
=
x2
y2
=
1) over-stressing causing unacceptable deformations or

breakage,
2) collapse of the coupling or parts of it,
3) malfunction of mechanisms inside the coupling,
4) uneven seal loads around the circumferences caused by
eccentricity between coupling and pipe.
Misalignment between the pipe ends (radians).

offset between pipe ends
Half coupling length (bridging one pipe end)
For Category 2 couplings, the misalignment angle b is

calculated based on deflections caused by the contact forces
inside the coupling.
The pipe straightness tolerance shall be included, either as an
addition to the pipe diameter, or as part of the misalignment
angle b.
The radial seal load during the seal pressure test shall be
established and compared to the limiting seal load. The
limiting seal load shall be based on tests or documented
experience.
Guidance note:
The seal test pressure could be applied to an annulus external to
the pipe, and could therefore be lower than the pipeline test
pressures. This is because the internal pressure normally
improves the sealing capability due to the pipe expansion
compared to external pressure, which compresses the pipe.
However, an external differential water pressure due to
depressurisation of a gas pipeline will have the opposite effect
and must also be considered.
5.7 Misalignment limitations

The above illustrates in-plane limitations. The global
misalignment and offset, i.e. in two planes, must be used to
control actual conditions. For this purpose, the root mean
square for conditions in two 90 degrees planes can be
applied.
Examle:
For second entry, plane v and h:
b=
x2 =
bv2 + bh2
x22v + x22h
5.8 Activation
The bending moment caused by the activation process of the
coupling shall be calculated. This applies to couplings which
bridge two misaligned pipe ends, each with stiff supports.
The calculation of this moment shall include:
1)
2)
3)
4)
misalignment,
pipe straightness,
stiffness of pipe ends and their fixation,
ability of the coupling to absorb the misalignment
without aligning the pipes.
The stresses of the internals of the coupling caused by the

activation shall be evaluated. This shall include a risk
assessment for:
DET NORSKE VERITAS
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September 1999
5.10 Monitoring and control

5.10.1
General
Diverless installation of a subsea pipeline coupling requires:

1) A system to control the forces and displacements,
2) Forces to displace and manipulate the pipe ends and the
coupling,
3) A monitoring system to verify that manipulations are
made within the limits for the pipe and coupling ,
4) A monitoring system to verify that the coupling is made
up properly,
5) A test and monitoring system to verify that the coupling
seals.
Guidance note:
The monitoring system may comprise a range of TV cameras,
sensors for alignment, sensors for displacements and force and
pressure sensors, etc. The monitoring system shall verify that
each parameter that can cause a failure is within acceptable
limits.
A general principle for the monitoring system design is that:
Failure of a monitoring system (sensor) shall not stop the

operation.
A redundant system or alternative method is required to
control and monitor the operation. On this basis, the design
should be such that a TV can monitor all critical issues. This
could include monitoring without sensors.
5.10.2
Acceptance criteria
The connection operation shall be planned and conducted in

such a manner that the specified functional requirements are
met, i.e.:
controlled within the established limitations

monitored
that the fulfilment of the functional requirement (e.g.
seal test) is recorded.
The records shall serve as documentation of the fulfilment of

the requirements.
The manufacturer of the coupling shall identify and list the
functional criteria to be checked.
DET NORSKE VERITAS
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September 1999
6. Design
3.4.1
Deflections/damages caused by
installation.
6.1 General
3.4.2
Dirt on the sealing surfaces
The design of the coupling shall demonstrate safety against

possible failure modes. A Failure Mode and Effect overview
shall be established for each coupling type.
The method used to demonstrate safety against possible
failure modes shall be qualified.
3.5
4
Lack of sufficient seal test pressure
Fail to lock
4.1
Axial capacity insufficient due to:

4.1.1
Lack of friction.
4.1.2
Mechanical locking fails.
6.1.1 Failure modes
4.1.3
Pretension insufficient
The general failure modes for couplings are:
4.1.4
Secondary effects from internal pressure.
4.1.5
Poisson effects not considered in design.
4.1.6
Eccentricity
4.1.7
Relaxation
4.1.8
Corrosion
1)
2)
3)
4)
Fail to install on the pipe,

Activation of coupling causes damage to the pipe,
Fail to seal (leak),
Fail to lock.
Conditions for prevention of failure modes type 1 and 2 are

considered in Sec. 5.
4.2
As an example, general failure modes type 3 and 4 are

identified either for all coupling types, or for particular
groups, in the following:
3
Micro motions caused by:

4.2.1
Uneven axial load transfer distribution

between pipe and sleeve. Loads
exceeding the limits in parts of the
coupling.
4.2.2
Accumulation of local axial

displacements between coupling and pipe
caused by forces/temperature changes.
Fail to seal (leak)

3.1
3.2
3.3
3.4
Loss of seal compression loads due to lack of

sufficient elasticity to compensate for relaxation
caused in some operational conditions by:
3.1.1
Local plastic yield of pipe
3.1.2
Local plastic yield of seal support

structure, back up rings or metal seal
Load case not considered e.g.:

3.2.1
Compressive/expansion load effect from

temperature and the additional expansion
of polymer seals.
3.2.2
Effects transferred from the locking

mechanism.
3.2.3
Effect from swelling (chemical reactions

to polymer seals).
3.2.4
Local distribution from unsymmetrical

conditions.
3.2.5
Seal axial loads/displacement/wear:

3.2.5.1
Changing axial
loads/displacement.
3.2.5.2
Temperature effects.
4.3
Fatigue (seldom design case)
4.4
Torque (could occur during the last phase of the

installation)
6.2 Material properties

The following parameters shall be specified, when relevant:
1) Material strength: (For steel see: DNV OS-F101, and
for polymer materials see: API Bul 63);
2) Thermal expansion coefficient;
3) Friction coefficient;
4) Galling limit;
5) Thermal effects on the mechanical properties of polymer
materials;
6) Swelling of polymer materials in the specified
environment;
7) Chemical resistance for the specified environment;
8) Corrosion resistance, particularly for seals and seal
supports, for the specified environment.
6.3 Strength capacity
Seal micro performance fails

3.3.1
Seals ability to fill/seal discontinuities in

pipe.
3.3.2
Seal/back-up ageing/corrosion.
3.3.3
Extrusion of polymer seals
3.3.4
Explosive decompression of polymer

seals
6.3.1 General
A coupling shall have sufficient strength capacity to convey
the pipeline forces, forces generated in the coupling, and
installation forces with a safe margin. This margin is defined
in Sec. 2.1
Requirements to material usage factors for the pipeline and
components on the pipeline are defined, either directly or by
reference to other standards, in DNV OS-F101
Seal protection fails
DET NORSKE VERITAS
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6.3.2 Loads
The coupling design loads (according to Sec. 1.4.1) shall, at
least, be:
equivalent to the load capacity of the pipeline; or,

for axial-, torsion- and fatigue loads, equivalent to the
maximum loads in operation, during installation and
testing.
(The maximum axial pipeline operational forces are

established in Sec.4.)
An overview of loads and load combinations shall be
established. Main load conditions to be included are:
A coupling shall have sufficient seal capacity to isolate the

specified fluid at specified differential pressure, temperature
and time, with a margin as defined in Sec. 2.1. This applies
to operation, pressure testing, and after depressurising the
pipeline.
Each seal in a series shall be designed for the full differential
pressure. The seal system shall be designed to enable a seal
test without requiring pressurisation of the pipeline.
6.4.2 Design capacity
Calculations or tests of the seal system response to the load
conditions shall be carried out. This shall include:
Item of
concern:
Calculations/Tests:
Soft seals
clearance to
seal.
Circumferential clearance distribution as function

of load conditions including unsymmetrical loads
(bending), pipes geometry and manufacturing
tolerances.
Stresses in back up rings or strengthening devices
and safety against their failure modes (e.g.
warping, material plastic yield)
Hard seal
loads.
Circumferential seal contact load distribution as

function of the load conditions including:
unsymmetrical loads (bending) pipe geometry
and pipe surface discontinuities.
Annulus seal
test pressure
limit.
If there is an annulus seal test feature, calculate

the maximum annulus test pressure limit both
with respect to pipe failure and seal failure.
Load Type
Conditions, Parameters
Internal and external

pressure
Pipeline design and test

conditions.
Seal test pressure.
Maximum seal diameters.
Bending moment
Pipeline capacity specified.
Tension, Compression
Pipeline capacity specified or

limiting loads
Torque
Pipeline capacity specified or

limiting loads
Bending fatigue
Pipeline capacity at the butt weld

specified or specified number of
bending cycles related to bending
moment.
Temperature
Maximum and minimum related

to the above capacities and limits.
Soft seal
volume
changes
Calculate the volume changes caused by the fluid

in contact and the temperature changes.
Installation
Maximum forces limitations for

interaction with the pipe and on
coupling internals.
Soft seal fluid

migration.
Calculate the migration rate of the fluids to seal

based on the material specification, at maximum
differential pressure and temperature.
6.3.3 Load responses

Couplings respond to loads by stresses and deflections. The
principles used to predict stresses and related acceptance
criteria are discussed in Sec. 2.1. This also applies to the part
of the coupling capacity which is based on friction. General
methods for stress calculations and related acceptance
criteria are established in the standards referred to in DNV
OS-F101 or other recognised standards.
Discussion of seals aspects and application are presented in

Appendix A.
Guidance note:
Some types of couplings depend on friction for the torque
capacity. Friction can also contribute to the tension capacity.
Coupling based only on friction are rare. Assessments of the load
response for a friction based coupling, however, indicate general
responses for couplings. This can be applicable when the
attachment between the coupling sleeve and pipe-wall is
uniformly distributed.
6.4 Seal capacity

6.4.1 General
The sealing principles and seal installation sensitivities are
defined in Sec1.1 and 1.4.2.
DET NORSKE VERITAS
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September 1999
7. Testing
7.1 Test philosophy
The test philosophy is briefly mentioned in Sec. 2.1 items 5,
6 and 8.
The extent of the required tests depends on the design type,
confidence in analyses, and the extent of documented
experience.
A qualification program shall be established based on the
above aspects. This program shall determine:
the tests to be carried out,

the purpose of the test,
the parameters to be measured and recorded,
the accuracy of these measurements and
type of analysis of the test results to enable correlation
with the design analysis and limiting design conditions.
The typical tests are:

1) Basic tests, such as testing of material strength, seal
capacity, extrusion gaps etc.
2) Type tests (Qualification tests), which verify the
functional requirements of a new type design. This type
test can be combined with the FAT (see below) for the
coupling tested.
3) Factory Acceptance Tests (FAT), which verify the
manufacturing and assembly of a coupling which is
already type tested. FAT for couplings that are not
designed for reuse could be limited to dimensional
measurements and check for material compliance with
the design criteria.
4) Final Tests which verify the completed installation.
Examples of typical tests are described in Appendix B
DET NORSKE VERITAS
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September 1999
6.
8. Documentation
8.1 Documentation
Manufacturers Design and Fabrication Resume (DFI)

The DFI resume shall identify possible requirements to
inspection and maintenance and give guidance for
possible repair/retrieval.
Manufacturers Certificate of Conformity with specified
criteria.
8.1.1 General
7.
General documentation principles are presented in DNV

OS-F101and this publication. The documentation should be
available and submitted for assessment as agreed.
Requirements for such documentation are detailed further in
the following:
8.1.6 Installation
8.1.2 General documentation:
1.
2.
1.
2.
3.
4.
Description
Installation principles
Main specifications and limitations
Arrangement drawing with position numbers.
3.
4.
8.1.3 Qualification
5.
Documentation of:
1.
2.
3.
4.
5.
6.
Documentation of:
Analysis related dimensional drawings and materials,

and tests related to the design and installation principles.
Identification of possible failure modes and
documentation of a reasonable safety margin against
these failures.
Interpolation/extrapolation methods to be applied for the
actual designs.
Material specifications.
Principles of manufacturing and quality control
including main principles of factory acceptance test
procedures.
Limitations, assumptions and requirements to
installation tools and installation procedures.
8.1.4 Design
6.
7.
8.
Lay out drawing of the installation

Dimensions including tolerances and material
identification of the pipes to be connected
Pipe and coupling manipulation documentation for
compliance with both pipeline- and coupling design
requirements.
Inspection records of pipe end cut geometry, pipe
surface roughness and cleanness, pipe ends alignments
Documentation confirming coupling make-up within
prescribed limitations.
Leak test report with P&ID (Process & Instrument
diagram) of leak test system
Final inspection documentation
Installation contractors Design, Manufacturing and
Installation Resume
8.2 Qualification check list

Methods used for qualification depend on the type of
coupling. The Appendix C to this Recommended Practice
presents a checklist for use in the qualification. The list is
split into 3 main chapters: A for input parameters, B for
parameters to qualify, and C for documentation.
The qualification part, the B list, is furthermore split into
two main columns, one for analysis and theory and another
for tests.
Documentation of:
1.
2.
3.
4.
8.3 Quality assurance
Specifications and limitations

Detailed dimensional drawings
Identification of materials
Design analysis
The manufacturer and installation contractor shall:
8.1.5 Manufacturing
Documentation of:
1.
2.
3.
4.
5.
Material test certificates

Manufacturing records on bolt pretension, welding
procedures, welding qualification and NDE personnel
qualification.
Dimensional measurement report on key dimensions
Test reports
Unique identification (for tracetability of coupling and
main components)
perform design, manufacturing and installation

according to generally recognised quality assurance
procedures; and
follow recognised standards/acceptance criteria.
Guidance note:
A method to document the quality of the coupling is described in:
DNV SS-301 Certification and verification of submarine pipeline
systems
8.4 Traceability
Each installation shall be traceable to the installation records
(documentation), manufacturing records and qualification
documentation.
DET NORSKE VERITAS
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September 1999
Couplings with wedging effects may increase the radial
contact forces by pipe tension. Increased radial contact forces
cause pipe contraction and may cause an axial displacement
of the pipe inside the coupling.
Appendix A Coupling Capacity

A.1 Coupling Strength Capacity
A.1.1
General
The locking capacity depends on the attachment method to

the pipe:
the attachment is nearly uniform along and around the

pipe employing many balls or teeth, similar to a friction
based coupling,
it depends on local attachments such as edges, few teeth
or few balls penetrating into the pipe surface.
Axial pipe compression may reduce the contact forces and

cause sliding of the pipe inside the coupling.
Likewise will this couplings capacity be reduced for axial
compressive pipe loads unless the pipe ends meet a recess in
the coupling or the other pipe end.
Torsion
The structural strength of the coupling parts and the locking

capacity of a coupling shall be sufficient to convey the
pipeline forces. Parameters of concern are discussed as
relevant for the various coupling groups as follows:
A significant torsion capacity is seldom required. The torsion

capacity is related to the contact forces multiplied by the
friction coefficient and contact radius. Local gripping by
balls etc.,which prevents rotation of the pipe, improves the
torsion capacity.
Bending
Temperature
The bending strength of the sleeve governs this together with

the pipe ability to convey the bending moment and transverse
shear forces. A sleeve will, however, increase the pipeline
stiffness locally.
Normally the pipe is warmer than the sleeve. This causes

some increased contact force between the coupling and the
pipe, dependant on the design. Different thermal expansion
coefficients of sleeve and pipe will, however, also affect this
contact force.
Contact forces
The radial contact forces between the pipe and the sleeve
govern the capacity to transfer axial and torque forces in
combination with locking coefficient (the efficiency of the
locking).
This radial contact force is generated by the pretension and
the internal pipe pressure. This force is further increased by
pipe tension for couplings with wedging effect. (Sec 9.1.7)
The radial contact force is limited by either the collapse
strength of the pipe, or the radial stiffness of the sleeve.
Pressure
Internal pressure will expand the pipe and hence may
improve the locking capacity. This load type may therefore
not be the dimensioning for the coupling.
Fatigue
A significant fatigue capacity is seldom required.
FEA/testing can be applied to demonstrate fatigue capacity.
Some aspects of the coupling types are discussed below.
A.1.2
Symbols
The following abbreviations are employed in the formulae

that are derived in the below sections. Note that in the
formulae subscripts of s and p are used for sleeve and
pipe respectively. See also Sec. 1.9.
D
Outer diameter of the pipe. It may be assumed

that the difference (et) between inside
diameter of sleeve and outer diameter of the
pipe is negligible compared to the diameter of
the pipe. Therefore the outside diameter of
pipe may be taken equal to inside diameter of
the sleeve.
Length of contact surface between sleeve and

pipe
ef
Change in diameter due to tension force
et
Shrink fit. Difference in inner diameter of

the sleeve and outer diameter of pipe.
etm
Shrink fit produces a contact pressure, which

generate a fraction of yield stress of pipe.
ep
Change in outer diameter of pipe
es
Change in internal diameter of sleeve
Only relative small tension capacities are possible to verify

by a pressure test alone.
An external differential pressure can occure in gas pipelines
after depressurization. This load condition tends to contract
the pipeline diameter and may therefore reduce the tension
capacity of the coupling.
Tension/Compression
Pipe tension tends to contract the pipeline diameter due to
the Poisson effect. Thereby the radial contact forces may be
reduced for couplings which have no wedging effects,
resulting in a slight reduced tension capacaty.
DET NORSKE VERITAS
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September 1999
Thickness
Tm
Make up temperature
To
Operational temperature for sleeve
Temperature difference between pipe and

sleeve
A.1.3
A.1.5
General compression fit
Most couplings, except for the wedging types, are dependent

on initial high compressive forces between the pipe and the
sleeve.
Figure A-1 illustrates a general compression fit between
cylinders.
Pipe collapse
The contact forces during/after make-up are limited by:

Type 1.
The collapse strength of the pipe for

uncontrollable radial deformations.
Type 2.
The yield strength of the pipe if the radial

deformation is controlled and equal all around.
Some couplings can cause the above types of pipe collapse

under the following conditions:
L
ts
tp
Figure A-1 Illustration of the compression fit ("Shrink

fit")
et
The seal is best achieved by local surface yield occurring

circumferentially between the two surfaces during the
forging process. Internal ribs in the sleeve are beneficial for
this purpose. Internal ribs also improve mechanical locking
in the axial direction and thus improve the axial force
capacity.
= e p + es
Friction;
Type 1
During make-up
Grip, Balls (Wedged);
Type 2
During make-up and

tension of the pipe
Flanged;
Type 2
During make-up
A.1.6
Locking
Friction factors
Where:
Several types couplings partly depend on friction.
et,
shrink fit,
The friction coefficient depends on a range of factors:
ep
change in outer diameter of pipe
es
change in internal diameter of sleeve

respectively.
1)
2)
3)
4)
A.1.4
Expanded sleeves
One type of forging process expands the pipe to obtain a

compressive radial load between an outer sleeve and the
pipe. The forging sequences are:
1) Expanding the inner pipe until yield stress
2) Continue the expansion by yielding the inner pipe within
the limit of :
An acceptable permanent deformation and

An acceptable stress of the sleeve
Relieve the internal forging force. This causes the
sleeve to elastically shrink whilst pipe has
experienced a permanent (plastic) deformation.
static or dynamic
surface finish
material combinations
possible lubricants
There are no distinct limits between mechanical locking and

friction. Very rough surfaces tend to increase the locking
capacity .
Common used static friction coefficients steel/steel surfaces
range from 0.1 to 0.6. Sliding friction can be less. Note
however, that NS (Euro code 3) specifies slip factor
(friction coefficient) to be used in friction dependant
connections from 0.2 to 0.5 dependant on the surface
treatment:
The remaining compressive force between the pipe and the

sleeve must be sufficient to:
assure a locking in the axial direction, and

to seal.
DET NORSKE VERITAS
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September 1999
Slip
factor
Surface
0.5
Surfaces blasted with shot or grit, with any loose rust

removed, no pitting.
Surfaces blasted with shot or grit, and spray-metalled
with aluminium
Surfaces blasted with shot or grit, and spray-metalled
with zinc-based coating certified to provide a slip
factor of not less than 0.5
Sleeve
0.4
Surfaces blasted with shot or grit, and painted with a

zinc silicate paint to produce a coating thickness of
50-80 micron.
0.3
Surface cleaned by wire brushing or flame cleaning,

with any loose rust removed.
0.2
Surfaces not treated
A.1.7
Wedge 1
R
Wedge 2
Grip teeth
Pipe
Figure A-2 Configuration of a simple connection

providing locking by wedges
Pipe expansion into grooves in sleeve
Geometric locking
External local forge, where balls provide the lock

The point loads from the balls are to be distributed.The size
of the balls is the key parameter for determining the number
of balls used, and this is limited by geometrical conditions
and local deformations.The minimum ball diameters will
therefore be determined based on:
1)
2)
3)
4)
clearance to bridge between pipe and sleeve

deformation of pipe
deformation of sleeve
strength
The locking is based on a local plastic yield of the pipe

caused by the radial force from each ball. Local buckling of
the pipe wall, instead of the required local plastic yield, is
avoided by applying a sufficient amount of balls around the
circumference. The diameter of the balls must then be
optimised, to obtain sufficient indentation and number of ball
rows for sufficient holding capacity.
External grip from teeth on wedge
Locking is obtained by an axial load generated by bolts
which force the wedges into the pipe. During activation teeth
on the wedges penetrate in the pipe surface and cause
locking, shown in Figure A-2
The contact pressure between pipe and wedge depends on the
axial activation force, friction coefficient and the magnitude
of the taper angle of the wedge.
Analysis and test of a typical coupling indicates for the

following load conditions:
1) Simple Tension: The pipe waves in the grooves will be
very slightly smoothed, but this Poisson effect will not
affect the tensile capacity. The contact pressure at the
edges due to tension will increase for the coupling
because of the increase of the axial component.
2) Axial Compression: The pipe waves in the grooves will
be slightly deeper but this will not affect the axial
capacity.
3) Tensile load capacity: The few sharp edges on the
sleeve penetrates into the pipe surface. Pipe tension
causes high stresses around the pipe circumference
thereby limiting the tension capacity when only few
edges carries the load. The pressure will not improve the
tension capacity.
A.1.8
Longitudinal force distribution
Connections will have a longitudinal shear force distribution.

This depends on the thickness of pipe and sleeve, elasticity
modulus, length and type of joint between pipe and sleeve.
Generally, the radial load is expected to be higher at the
sleeve ends due to effects from the undisturbed pipe. Thus a
friction shear capacity will be higher close to the sleeve ends.
This is an effect which, to some extent, may compensate for
the higher shear stress at coupling entrance caused by
external forces.
There will be some shear stress due to a temperature
gradient. The change in shear stress due to this temperature
gradient will in most cases be small compared to that caused
by tension. The impact of temperature to shear stress
decreases for couplings with larger length. The effect of
fluctuations of temperature will in most cases be small.
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A.1.9
Micro motions
Each temperature cycle may cause an internal relative

longitudinal displacement between the pipe and sleeve.
When this motion is combined with tension, there may be a
small resultant longitudinal sliding for each temperature and
load cycle for a fully friction based junction.
For the majority of applications, however, the resultant
effects are not considered to be of concern to the long term
locking capacity.
A.2 Seal Capacity

A.2.1
Discussion
Soft seals
The seal manufacturers normally recommend limitations for
use of the seal, including pretension for pressure activated
seals as well as limits for extrusion gaps as function of
pressure, temperature, time and load type. These
recommendations shall be documented, however, as the
application of soft seals for couplings is often outside normal
use, further qualification may also be required.
Metal seals
The make up pressure for the gasket must significantly
exceed the material yield strength of the seal material (or
pipe material). Otherwise the seal material will not flow into
the discontinuities and a seal cannot be obtained. These
requirements can be relaxed if all discontinuities are
removed completely, but this is seldom practical for pipe
surfaces.
Consequently wide metal gaskets will be impractical as this
would require unacceptable high radial loads against the
pipeline. Such high loads could cause pipeline collapse due
to the resultant high hoop stresses.
Therefore, radial metal seals for pipelines have thin sealing
areas, often obtained by sharp edges penetrating into the
pipeline.
A.2.2
Compressive loads
Sealing action depends on a compressive load between the

seal and its sealing surface. The contact pressure must
exceed the pressure of the fluid to seal. A safety factor must
be applied to assure this condition.
A.2.3
of the pipe. High loads close to the ends are more likely
to cause plastic deflections.
2) A distributed circumferential load on a pipe length less
than 0.1 diameter gives equal pipe shell global responses
similar to that from a line load of same force (The
contact stress reduces proportional to length)
3) Plasticity of the pipe wall can be caused by high seal
loads. This starts with yield related to plate bending
(merodonial bending) before hoop yield. Formulas for
the plastic behaviour of the pipe wall can be developed
based on the plastic capacity of the pipe wall and
calibration.
4) Local plastic yield of the pipe surface is required for
metal seals. Formulas for the penetration depth can be
developed based on the theory related to Vickers
hardness measurements and calibrations.
A.2.4
Thermal effects
Polymers
Thermal expansion of rubber in an enclosed space can be a
matter of concern, as the thermal expansion coefficient of
polymer materials can be more than 10 times that of steel.
Typical conditions for a polymer seal tightly enclosed within
a steel boundary are indicated below, assuming:
1) equal temperature in the steel and the seal;
2) a thermal expansion coefficient of 11 times that of steel;
3) an incompressible seal.
Steel stress magnitude: = E t = 25 t
Thereby unstressed steel with yield strength of 350 MPa will
yield at a temperature 14 C higher than at make-up.
The steel will, however, be pre-stressed, and hence will yield
at a lower temperature.
The magnitude of the permanent relaxation will be as
follows, by assuming:
1) Plastic yield in one direction.
2) Typical polymer seal thickness l in this direction:
50 mm
3) Temperature increase from make-up: 50 oC
4) Pre-stressed steel to yield.
Relaxation magnitude: t l = 0.3 mm.
Consequently, the effect of different thermal expansion
coefficients must be considered in design, i.e. there must be
sufficient space for this expansion to avoid such effects.
Uniform loading
Circumferential seal loads
Fluids
Some areas of concern are:
The expansion coefficients for trapped fluids in cavities must

be considered in the design:
1) Loads closer than 0.2 diameters to the end cause

significantly more inward deflections of the pipe wall
than if they were further away. Elastic deflections at the
end can exceed 4 times the deflections on a midsection
1) Hydrocarbon gases (mainly methane) initially at 205 bar

and +4 C, then heated to 60 C typically gives an
increase to approximately 2.1 times the initial pressure.
DET NORSKE VERITAS
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2) The thermal expansion coefficient of water depends on
the temperature, pressure and salinity. Fresh water has a
thermal expansion coefficient of 0 at +4 C.
3) Typical oil has a thermal volume expansion coefficient
of 0.001/ C
A.2.5
Axial load effects are of most concern to thin metal seals.

Thermal effects
Swelling
Polymer materials tend to expand due to absorption of fluids,

and this is to be considered in the design.
A.2.6
1) Seal displacements over local discontinuities of the pipe

surface;
2) Wear.
Eccentricity
Flexibility in the systems design must compensate for the

possible eccentricity between the seal and pipe.
The seal is often located at some distance from the locking of

the pipe. The pipe section between the locking and the seal
will expand by temperature, whilst the sleeve external to the
pipe will expand less due to the cooling effects from the
water. Therefore, similar effects as above must be considered
in the design.
This eccentricity may be caused by:
A.2.8
1) External forces acting on the pipe ends during

activation;
2) The function of the locking mechanism and positioning
of the coupling;
3) Pipe deviations from straightness;
4) Pipe deviation from roundness.
Water block
A.2.7
Axial effects
Load effects
Installation
Water trapped in cavities during make up prevents further

action. This is of particular concern to the seals made by
expansion of the pipe. The pipe is intended to expand into
grooves of the sleeve, but this can be prevented by water
located in the groove. Several designs therefore apply a resin
filled with gas bubbles to reduce the water block effect. Such
resins must, however, be qualified for the water depth they
are installed. Deep water requires relatively compact resins
to avoid collapse of the gas bubbles inside.
Elastic deflections of pipe and sleeve due to the axial pipe

forces can, for some designs, cause a relative axial
displacement between the pipe and the seal. This can be of
concern for long term use, and should therefore be
considered in the qualification plans. The concern is:
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Two types of gaps are of concern:
Appendix B Typical tests

B.1 Basic tests
B.1.1
Introduction
Basic tests establish limiting parameters which are not

established by analysis. Basic tests can be used to reduce the
extent of Type tests (Qualification tests) required in
combination with analysis. The following are examples of
typical basic tests:
B.1.2
Materials
Typical tests are related to material properties and are well

regulated by international and recognised standards.
Information can be obtained from literature and
manufacturers as indicated below:
1) Properties of metallic alloys are easily obtained for
commonly used metallic materials.
2) Relevant properties of non-metallic sealing compounds
(rubbers, plastic, carbon, etc.) are difficult to obtain.
Tests related to resistance against the various types of
corrosion are dealt with as for the pipeline itself.
Ageing tests of polymer seal materials are used to predict the
lifetime of a seal in specified environments and are therefore
time consuming. The test time can be reduced by an increase
of the test temperature, but cannot normally be reduced to
less than to 1/10 of the intended lifetime due to temperature
limitations of the materials. Therefore ageing tests must be
supplemented by detailed documentation for the materials.
B.1.3
Combined effects
Some combinations of design and material parameters

require separate tests for establishing limiting parameters.
Normally at least a number of 3 tests and specimens should
be used to indicate the possible spreading of results.
Such tests are as follows:
The first gap of concern is related to clearances to seal. The

size of the tested clearance gap must be determined
accurately, and can be affected both by the pressure and
temperature. The gap is either pre-set fixed or measured
during the test.
The second gap of concern is related to sealing against
discontinuities on the pipe.
The pressure can be applied either via a test fluid, or, for
larger compact polymer seals, directly as a compressive force
causing the intended internal pressure of the seal compound.
The term extrusion must be defined in relation to failure
mode of the seal. For a plastic and rubber seal as well as
back-up rings, this could address:
1) The permanent deformation into the gap as a ratio of the
gap size.
2) Plastic deformation of internal strengthening members
such as metal springs.
3) % fracture of reinforcement fibres.
Metal seals Tests
Metal seals must seal against the pipe surface including
defined surface discontinuities. Therefore sufficient plastic
yield of the pipe surface and/or the seal must be obtained.
Important test parameters are:
1)
2)
3)
4)
5)
6)
The determining parameter could either be:
Extrusion gap test of polymer seals.

This test establishes the relationship between:
1)
2)
3)
4)
5)
Size of clearance gap to seal,

Pressure to seal,
Friction,
Temperature,
Time.
Material hardness of seal,

Material hardness of pipe,
Shape of seal,
Load applied to seal,
Defined discontinuity of pipe,
For seals that can be marked during installation: defined
discontinuity of seal.
leak test, or
microscope investigations of the specimens being forced
together, combined with later full-scale test including
defined discontinuity.
Friction factor Tests
The seal manufacturers often give recommendations

(limitations) based on documented testing. However, the
intended seal applications can be outside such
recommendations and therefore require separate tests.
Most type couplings are affected by friction, either during

installation, make-up or in operation. Friction coefficients,
which are critical, are determined by tests. Important test
parameters are:
1)
2)
3)
4)
5)
Material combinations,
Surface roughness,
Specific compression load,
Velocity (dynamic friction),
Possible in-between fluids or contamination.
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The monitoring of forces which are required to move and to
compress is used to establish the friction coefficient.
The following describes typical Type tests.

B.2.2
B.1.4
Galling causes damaging of the surface finish as well as high

friction coefficients. The galling limits are determined in the
same way as friction coefficients but combined by a
microscope survey of the surfaces.
Polymer decompression limits (Explosive decompression)
Seals in gas systems can be damaged by high decompression
rates. Gas which was dissolved in the material at high
pressure can form bubbles when the pressure is reduced, and
this can result in seal damage. Important test parameters are:
1) Material type;
2) Size, shape of material and gas pressure exposed area;
3) Gas type, either the actual or a type, which exhibits
similar effects;
4) Pressure;
5) Saturation time;
6) Decompression rate;
7) Temperature;
8) Detection method of blisters.
B.2 Type tests

B.2.1
Test specimens
Galling Test
Introduction
A Type test (Qualification tests of the type) verifies, in

combination with analysis, the functional requirements and
safe operational limits of the coupling type.
The number and extent of the type tests depends on:
1) the extent of documented experiences;
2) the extent of the analysis performed;
3) the accuracy and conservatism of the analytical
approach;
4) the extent of basic tests performed.
After a Type test, there follows a Factory Acceptance Test
(FAT).
The Type test could be combined with the FAT. This
combined testing is practical when only one coupling of the
type is made.
The optimum qualification scenario should be analysis, basic
test and type test combined in a practical manner.
The Type tests include the extreme tolerance combinations
from dimensions, pressure, temperature, fluids, operation and
installation; for which the analysis is either incomplete or
indicates a particular risk of failure.
In addition, Type tests are used for verification of analysis.
This involves measurement of sufficient parameters
accurately to compare with those in the analysis.
Measurement and monitoring accuracy shall be documented.
Pipes
The pipes selected for type tests should represent the extreme
dimensional tolerance combinations, surface discontinuities
and material properties, unless the effect from these are
sufficiently covered by the Basic Tests and analysis. Such
pipes will, however, be difficult to obtain as the pipes will
normally have only some adverse combinations. The effects
from other combinations which are not available on the test
specimens must be covered otherwise.
The manufacturing method of the pipe shall be specified.
The detailed pipe dimensions shall be measured and
documented by a dimensional sketch, including information
with respect to:
1) Straightness in two planes (90 degrees apart) within one
coupling length from the end. The straightness shall be
recorded as deviations from the straight line at intervals
at maximum 1/10 the coupling length.
2) The accurate diameters shall be measured at sections:
At the ends
Where seals interact
One coupling length from the end
Half a coupling length from the end
At maximum and minimum straightness deviation.
3) Each cross-section for diameter measurements shall be

measured at 4 diameter positions equally spaced around
the circumference.
4) Local imperfections (welds, undercut, artificial
imperfections). The sketch shall show depth (height),
length, shape and curvatures. Photographs and plastic
replica can be used to supplement the sketch.
5) Wall thickness shall be measured 8 places equally
spaced around the circumference at each end.
6) End cut evenness or chamfer.
The pipes shall be marked for identification of the
measurement-positions and for the intended axial and
angular location of the coupling.
Test certificates valid for the particular pipe shall document
actual material properties. Hardness (Brinell or Vickers)
shall be measurements in weld areas.
Coupling
Drawings with dimensional tolerances shall be available.
The actual dimensions of the critical parts, such as minimum
internal diameter, shall be recorded with an accuracy of at
least 0.1 mm measured at, or transformed to, 20 oC ambient
temperature.
Material test certificates shall document the actual material
properties for both metals and seals.
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B.2.3
Installation
The installation test shall simulate exaggerated actual

installation, i.e. design conditions with a margin (See Sec.
2.1).
This shall include the coupling maximum design limits with
respect to pipe minimum end chamfer (if any), maximum
misalignment (and pipe straightness deviation), and
eccentricity between pipes and coupling including a margin.
Furthermore, the stiffness of the pipe supports, the support of
the coupling, as well as effects from gravity/buoyancy, shall
comply with the coupling limiting specifications. Thereby
the limiting forces and critical seal interactions can be
simulated during the installation test when the coupling is
displaced on the pipes.
The displacement shall be performed with actual maximum
specified velocities.
The basis for the test procedure/test rig set-up is:
1) An overview of the critical tolerance combinations for
installation;
2) Applied safety factors on tested tolerance combinations;
3) Stiffness of pipe ends including sub-sea fixation, if the
installation causes pipe deflection that may have an
adverse effect;
4) Stiffness of coupling support, if it may have any adverse
effect;
5) Weights dry and submerged;
6) Displacement velocities;
7) Possible different effects from dry test versus submerged
test.
The coupling shall be removed after installation from the
correct position, and the internals shall be inspected for the
interactions with the pipe. The seal area is of main
importance.
The installation test shall be repeated to cover all critical
tolerance combinations, and at least 3 tests shall be
performed.
All parameters mentioned above, including the seal visual
appearance, shall be recorded and compared with the
acceptance criteria. Photographs shall also document
interaction marks.
B.2.4
Activation
The activation test shall simulate the most adverse design

conditions with a margin.
The most critical tolerance combination for activation should

be selected. This will normally be the thinnest pipe wallthickness, largest clearance between coupling and pipe, and
largest misalignment (and pipe straightness deviation)
combined with largest stiffness. Furthermore, the coupling
shall be positioned at its maximum specified deviation from
one pipe end. This deviation shall be in the most critical
direction. This will result in a shorter distance between the
coupling seal and pipe end.
The basis for the test procedure/rig set-up is:
1) overview of critical tolerance combinations for
activation;
2) a margin applied to these tolerance combinations for
determining tested combinations;
3) stiffness of pipe ends including effects from sub-sea
fixation to alignment frames, if the activation causes
internal bending moments inside the coupling;
4) weights dry and submerged;
5) possible different effects from dry test versus submerged
test;
6) activation procedure;
7) monitoring and measurement procedures.
Other tests normally follow on from activation tests.
Couplings which enable repeated activation shall be subject
to at least 3 activation tests.
The deactivations shall be monitored as the activation.
B.2.5
Strength/leakage
Type test documentation of the coupling strength/tightness

shall normally be carried out to the design conditions, with
adjustment for actual material properties, dimensional
tolerances, and with an safety factor in addition.
Alternatively, the coupling can be tested to failure.
The basis for the test procedure is:
1) Design capacity specification for separate loads and
combined loads.
2) A margin between design conditions and test conditions.
3) Actual dimensions and yield strength of the pipe for the
test.
4) The activation condition which gives the least strength
capacity.
5) Measurements/monitoring of longitudinal (and
rotational) displacements between coupling and pipe as
function of the load.
6) Possible strain gauge measurements for verification of
the analysis, supplement to the analysis and for
determination of loads
7) Leak detection measurements
Leaks and unacceptable permanent deformation and
displacements are rejection criteria.
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Pressure test
Fatigue test

1) Test pipes with end caps
2) Pressure causing a defined hoop stress utilisation
depending on the application, e.g. 0.96 of the actual
yield strength of the test pipe.
Only a few pipelines are subject to alternating bending loads

of concern. The pipe itself, at its connection to the coupling,
will in most cases represent the weakest point of the
connection with respect to fatigue. The general limiting
fatigue resistance of the pipeline is at pipeline butt welds.
Pipe fatigue criteria are described in DNV OS-F101
Tensile test without pressure
For most pipelines, the tension capacity does not need to

meet that of the pipeline.
1) Specified maximum alternating bending moment as a

fracture of the bending yield capacity of the pipe tested.
2) Number of cycles with this load.
3) Distribution of magnitude of bending moments and
higher number of alternating loads.
4) A small insignificant internal (or annulus) pressure to
check the seal tightness.

1) A pipe tension, without significant internal pressure, as a
fraction of the yield capacity of the actual test-pipe.
2) A small insignificant internal (or annulus) pressure as
necessary to check the seal tightness.
Temperature test
Compression test without pressure
A test can document the compression capacity in couplings
where:
the pipe ends do not meet each other,

the pipe ends do not meet a recess, and
an axial pipe displacement inside the coupling can cause
negative effects.

1) A pipe compressive force as a specified fraction of the
yield capacity of the actual test-pipe.
The analysis shall show whether the temperature reduces the

strength/seal capacity more than that related to the material
strength reduction. From this analysis, important
combinations with any of the above tests, with part-loads,
can be established and will form the basis for test procedures
to assure the strength capacity at elevated temperatures.
Temperatures of concern are:
1)
2)
3)
4)
Maximum and minimum fluid temperature,

Water temperature,
Resulting temperatures of pipe and coupling,
Transient temperature distribution within the coupling
during start-up and shutdown.
External pressure test

Torque test
A significant torque capacity is needed for only a few
pipelines.
1) A pipe torque as a specified fraction of the torque yields
capacity of the actual test-pipe.
Deep gas pipelines connected sub-sea can have a particular

load case if the pressure is relieved from the pipeline. The
external pressure tends to reduce the interaction forces
between the coupling and the pipe due to additional
contraction of the pipe.
The external differential pressure resulting from the

water depth and the remaining internal pressure. The
limit would be the collapse pressure of the pipe.
Bending test
Combined loads
Bending moments can be introduced by the Activation test

described above.
The analysis shall show whether any of the specified

combined design load cases gives a smaller safety margin
against failure than the separate cases described above. Such
cases shall form the basis for testing of combined loads.
Possible combined loads are:
Bending moments introduced after activation will be of less

concern to couplings. Normally the pipe, and in some cases
the connection to the coupling, will represent the limit. A
small insignificant internal (or annulus) pressure should be
applied as necessary to check the seal tightness.
Internal pressure causing a hoop stress of the pipe of 80% of

actual yield strength combined; with
Tension (simulating a free span)
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September 1999
B.2.6
B.2.8
Seal Tests
Seal tests are partly included above.

In addition, the basis for seal test procedures includes:
1) Facility used to confirm the integrity of the connection
after make-up.
In case of lacking Basic tests:
2) Test of the relation between seal compressive load and
the pressure leakage limit
3) Test to confirm sealing at defined pipe surface
irregularities
4) Gas seal leak test.
5) Gas migration test. This includes detection by the use of
Helium combined with circulation of gas, outside the
seal, via a detector for Helium atoms in the gas stream.
6) Test to confirm the seal function in case there is a defined
eccentricity between the pipe and the coupling.
7) The seal test pressure confirming the integrity of the
installation should in general be 1.5 times the design
pressure to seal provided the maximum pipe stress is less
than 0.96 of the specified minimum yield stress. For an
annular seal test, the qualification test pressure may also
be limited by the collapse pressure limit for the exposed
short annulus pipe section.
An analysis shall show that the seal test pressure is
conservative (large) compared to seal conditions at the
pipe design pressures, where test pressures lower than
1.5 times the design pressure are applied. This can be
demonstrated through analysis by showing that the
specific seal pipe-contact pressure during seal test is
larger than the contact pressure at design pressure.
8) The seal test pressure to be applied sub-sea should be
qualified with a higher pressure applied during the
qualification tests.
B.2.7
Integration and Sub-sea
A sub-sea test shall be carried out. The test shall cover

features with different effects (possible failure modes) from
dry on land testing e.g. possible water block.
The tests shall, as a minimum, include:
1) Examination for marks and measurement for permanent

deformation of the pipe;
2) Examination of the coupling internals, in particular the
seals, before disassembly;
3) Measurement of critical dimensions of the coupling;
4) Disassembly of the coupling and measurement of critical
dimensions.
The measures shall be carried out with the same accuracy as
indicated above.
B.3 Factory acceptance tests

B.3.1
Materials and material combinations with possible failure

modes related to the sub-sea use shall be qualified by Basic
tests. Such features could be:
1) Volume elasticity and water absorption properties of
materials filling voids;
2) Swelling;
3) Electrical isolation;
4) Hydraulic systems pressure compensation systems.
Introduction
The Factory Acceptance Test (FAT) checks the

manufacturing of the coupling. It is, in principle, a spot
check of only some aspects of the coupling. The aspects of
concern are those related to possible errors in manufacturing.
Some types of couplings are designed for only one
activation, i.e. only for the actual pipeline connection.
Testing of such single activation couplings is therefore
limited to the Basic tests, Type test and Testing after
installation.
The following information regarding FAT applies in general
for couplings designed for possible reuse.
B.3.2
Manufacturing
The manufacturers quality control shall verify compliance

of material, dimensional tolerances and make-up forces with
the design documentation before assembly.
Critical dimensional tolerances and surface finish shall be
measured with an accuracy of at least 1/10 of the prescribed
tolerance band.
Where relevant, the magnitude of bolt pretension etc. shall be
recorded.
B.3.3
activation, and
pressure test.
Examinations
The coupling and the pipe shall be thoroughly examined after

the tests. This examination shall include:
FAT Testing
Couplings capable of activation, deactivation and

reactivation shall be tested. The test shall follow a procedure
with defined acceptance criteria. The acceptance criteria
shall be documented by the qualification work. Factory
acceptance tests can be carried out for nominal conditions
with respect to dimensional tolerances, pressures and time.
Typical tests for connection of pipes are as follows:
B.3.4
Activation test
The coupling shall be installed on pipes which are similar to

the actual pipes which the coupling is intended to connect.
The key parameters shall be identified and recorded during
activation and be within the prescribed limits.
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B.3.5
Pressure test
The coupling installed on the test pipes with end closures

shall be subject to a pressure test equal to the test pressure
intended for the pipeline.
B.3.6
Seal test
The seals shall be subject to a seal leakage test via the

annulus or the installation tool.
The test pressure shall be equal to that determined by the
qualification.
B.3.7
Deactivation test
The coupling shall be deactivated after testing. The key

parameters shall be identified and recorded during the
deactivation and shall be within prescribed limits.
B.3.8
Examinations
The dismounted coupling and the test pipe shall be examined

to check that the appearances/tolerances are within the
acceptance criteria, including:
Seals,
Grips (Connection area to pipe),
Marks on the pipe surface from seals and grips,
Dimensional measurements for possible plastic
deformations of sensitive coupling internals,
Dimensional measurements for possible plastic
deformations of the pipes.
Any possible need for replacement with new parts (e.g. seals)
following activation / deactivation shall be recorded.
B.3.9
1) Pipe conditions with respect to surface conditions and

the end-cut;
2) Pipe alignment and alignment of coupling relative to
pipe ends prior to installation;
3) Pipe gap between ends;
4) Contamination monitoring and control to avoid seal and
locking failure;
5) Displacement control of the coupling during installation
and control to avoid excessive forces;
6) Coupling position relative to pipe ends;
7) Activation displacements/forces monitoring/control to
assure activation within limits.
B.4.3
Testing
Sealing shall be tested to qualified pressure and time, with

testing either at annulus or via installation tool.
The time depends on the stabilisation period due to the size
and length of the pipe work connected to the test. Normally,
a much smaller time can be allowed compared to the
pressure test of the pipeline itself, due to the small volume
pressure tested; say 2 hours.
B.4.4
Dismounting
1) Temporary connections for control and monitoring shall

be sealed off after disconnection. The sealing off
integrity shall be verified by appropriate means,
dependent on the consequences of a leak through the
seal-off. The verification method shall be a part of the
qualification.
2) Forces applied to the connection after make-up and
testing due to the final pipe manipulation shall be
controlled within the connection limitations.
Insufficient Type tests
The FAT can be combined with Type tests, in case of

incomplete separate Type tests. Where such combination is
applied, the FAT must be extended to include the
requirements relevant for the incomplete Type test(s).
B.4 Installation verification tests

B.4.1
Introduction
Final tests verify that the completed installation complies

with prescribed criteria. In some cases, final testing consists
only of a leak tightness test.
However, the verification of the completed installation,
often comprises also monitoring and recording of parameters
which are important for assurance of the prescribed criteria.
TV or sensors are required as applicable to perform such a
monitoring.
The following describes typical testing.
B.4.2
Measurements, Monitoring and Recording
Measurements or monitoring of the limiting parameters can

assure that the coupling is installed within its limits. These
limits are normally:
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Appendix C Check List for Qualification

Det Norske Veritas
Rev.
Year
Revision record of list items:
Pipeline mechanical coupling
DNV Check list for Qualification
Type:
The following tables are split in

three:
Table A contains input parameters
Check list for qualification
Table B contains parameters to be

verified. Table B is split in two main
columns, one for analysis of
parameter effects and the other for
testing
Table B will be concluded by text

in bold and reference to the design
documents and test reports as the
project progresses.
Table C list documentation and main The last column will be filled in
technical correspondence
"OK" when all relevant
information is received, and items
to qualify found in order, or "NA"
for not applicable.
Table A Input parameters

Item
Parameter/ Failure mode
Unit
Spec.
Comment
Testing
1.
Actual Pipeline:
Ref:
Test pipe applied in

qualification and FAT:
1.1
Pipe dimension and Tolerances
1.1.1
External nominal diameter, D
mm
1.1.2
Wall thickness nominal,
mm
1.1.2.1
Wall thickness tolerance
mm
1.1.3.1
External diameter tolerance.

mm
External diameter diameter by tape
1.1.3.2
Out of roundness by gauge
mm
1.1.3.3
Local out of roundness
mm
1.1.3.4
Straightness for one pipe length

equal to coupling length
mm
Based on a coupling length

on a typical line pipe
section length with 0.1 %
(circular) deviation from
total length.
1.1.3.5
Total measured diameter tolerance

(by gauge, not tape)
mm
,+/-tape m dia.tol +/0.5*out.o.r.m.dia.tol.

Additions from local out of
roundness, straightness and
flattening during
installation are to be
considered based on the
likelihood of a
combination. Thereby a
sum of all extremes could
be avoided.
1.1.4
Corrosion allowance, internal
mm
1.1.5
Surface imperfections
mm
OD max - OD min.
Flattening during
installation might increase
the out of roundness
Common pipe spec: c)

weld undercut: 0.8 mm for
10 mm length. J) equally
for other imperfections
DET NORSKE VERITAS
Data
Check
31
September 1999
Item
Unit
Degrees
Spec.
Comment
1.1.6
End cut evenness
1.1.7
Chamfer on pipe ends to be defined
1.2
Pipeline forces/temperatures
1.2.1
Bending moment (operation and

coupling installation)
kNm
Max. expected
1.2.2
Tension without pressure

(operation and coupling
installation)
kN.
Max expected
1.2.3
Torque without pressure (operation kNm

and coupling installation)
1.2.4
Pipeline test pressure at coupling
MPa
1.2.5
Internal pressure at coupling
MPa
1.2.6
External pressure
MPa
1.2.7
Max temp:
1.2.8
Min Temp:
1.2.9
Alternating loads, magnitude and

number of cycles.
Start- ups including

pressure and temperature
1.3
Pipe material
Obtain typical material test

data
1.3.1
Material min spec yield strength
MPa
1.3.2
Material min spec tensile strength
MPa
1.4
Environment
1.4.1
Cathodic protection exposure

externally
1.4.2
Internal fluid
1.4.2.1. During operation
Gas, oil(contaminants: H2S,

CO2, sand, water)
1.4.2.2
List possible parameters of

concern such as time and
circulation rate.
1.4.3
Max. fluid temperature change rate C/ min
1.4.4
External fluid, salt water, possible

leaking fluids
1.4.5
Impacts from trawl boards
2.
Coupling
2.1
Dimensions
2.1.1
Length, max
mm
2.1.2
Diameter outer sleeve
mm
2.1.3
Dry weight
kN.
2.1.4
Wet weight
kN
2.1.5
Internal min. diameter
mm
2.1.6
Internal min. diameter of seals
mm
2.2
Locking
Parameters important to the

mechanical locking to the
pipeline
2.2.1
e.g. Radial make-up pressure

between pipe and coupling
Average pressure load

based on length of locking
2.3
Metallic materials
Certify material properties
2.4
Other materials
Certify material properties
2.5
Max. gap between pipe ends and

position accuracy
Possible internal water circulation

before and during coupling
installation,
mm
Max expected
Possible limitation caused

by coupling design
DET NORSKE VERITAS
Testing
Data
Check
32

September 1999
Item
Unit
Spec.
Comment
2.6
Max misalignment and offset of

pipe ends prior to and after final
positioning
Degrees
3.
Tool for installing the coupling

and aligning pipes
3.1
Pipe lifting capacity (H Frames)
kN,
3.2
Pipe transverse motion capacity (H kN,

frame)
3.3
Pipe alignment capacity (CIF)
Degrees,
kNm
Moment capacity for each

claw
3.4
Pipe joining force capacity (CIF)
kN,
Push/Pull capacity
3.5
Coupling axial displacement

capacity
kN,
3.6
Total coupling handling stiffness

vertical
N/mm
3.7
Total coupling handling stiffness

horizontal
N/mm
3.8
Relative bending stiffness of pipe

ends as fixed in the tool
arrangement
Nm2
3.9
Pipe diameter max. capacity
mm
3.10
Coupling max. length capacity
mm
3.11
Accuracy tolerances:
3.11.1
Coupling alignment relative to pipe Degrees

ends
3.11.2
Coupling relative to pipe end radial mm

offset
3.11.3
Pipe ends relative alignment
Degrees
3.11.4
Pipe ends relative transverse offset
mm
3.11.5
Pipe ends axial gap
mm
3.11.6
Coupling positioning axially
mm
The couplings ability to

tolerate misalignment
+/- capacity
Based on the combined

stiffness of the pipe ends
and the stiffness of the tool.
Combination of control and

monitoring accuracy:
DET NORSKE VERITAS
Testing
Data
Check
33
September 1999
Table B Qualification parameters
For . type
Items to be verified by
Item
Unit
Spec.
Items possibly to be
verified by
Analysis, ref. to literature or Test

doc.
1.
Interactions Coupling pipe:
1.1
Coupling makeup forces/geometry:
1.1.1
Installation loads/alignments (seal

protection)
Establish theoretical max

based on 1) geometry, on
stresses and seal safety 2)
pipeline properties/tool
limitations.
Verify by tests,
measure geometry and
forces, inspect for
adverse effects.
1.1.1.1
1)
Establish by calculations 1)
the contact forces against
sleeve, seals and pipe, 2) the
following stresses, and
utilisation against possible
collapse/damage as function
of bending moment on the
pipe and extent of pipe insert.
Decide the limitations

of the analysis, and the
possible consequences
for the extent of the
above test. Galling
between inner sleeve
and pipe ends can cause
local nipples on the
pipe that can harm the
seals.
1.1.2
Pipe joining forces applied by tool
Establish consequence on
moment and shear force and
the resultant effects
Include in above test.
1.1.3
Activation forces and tolerances
Calculate collapse pressure

and safety against collapse.
1.2
Relative effects between

coupling/pipe
1.2.1
Clearance radial/diametrical
Establish whether the

coupling or its internal parts'
deformation/ displacements
are within acceptable limits.
1.2.2
Activation
Establish possible utilisation

with respect to limiting
effects e.g.: 1)Forces (See
B1.1.3), 2)Stresses &
Buckling 3)Displacements,
4)Galling 5)Risk for water
block (See B4.1)
Conclude possible
parameters to apply in
test, Monitor e.g.:
alignment forces &
configuration/
activation forces/
displacements/
pressure/ stresses.
Record.
1.2.3
Relaxation of activation forces
Estimate based on previous

test results. Possible causes:
1) Release of activation
forces, 2) Uneven axial load
distribution, 3) Load
conditions causing local
yield. 4) Thermal internal
expansion forces caused by
different thermal expansion
coefficients.
Measure by strain
gauges
1.2.4
Temperature effects on locking
Calculate possible adverse

effects from temperature or
temperature changes.
(Possible effects by micromotions.) (See also B1.2.3)
Include in above test if

found of concern from
analysis.
1.2.5
Friction coefficient (For couplings

dependant on friction)
Establish by small
sample test possible
effects on the friction
coefficient from:
surface roughness, rust,
water and oil. Include
adverse effects in the
above.
DET NORSKE VERITAS
Data
Check
34

September 1999
1.2.5.1
Friction test fixture (Proposal):
1.2.4
Coupling capacity
1.3
Sealing
1.3.1
Measure friction and

forces between small
plates forced against
each other at realistic
conditions.
Calculate design capacity and
safety factors against failure
based on 1) symmetric, even
and round pipe ends 2) max
difference of pipe ends
geometry tolerances.
Perform tests (to be

agreed) and finally a
tension test to brake
without pressure.
Verify by strain gauges.
Overall seal capacity
Calculate theoretical seal

load based on 1) symmetry,
2) maximum deviation from
symmetry, Include seal
reactions to test pressure and
operational pressure and 3)
temperature axial expansion
of pipe versus that of the
coupling at the seal. 4) effects
from different thermal
expansion of enclosed sealing
materials.
Test annulus between

seals to a pressure
including safety factors
for installation tests.
Test conditions: most
adverse. Test to leak
should be considered as
a final test.
1.3.2
Local seal capacity
Correlate seal load between

small sample test and the
local load from the full scale
test. (This requires that the
radial seal load for the
various load conditions is
determined, Ref B1.3.1)
Test by small sample

test the effects from
small and larger local
pipe surface
discontinuities and
local seal damages.
Include adverse effects
in the above test.
1.3.2.1
Test fixture (Proposal):
Establish realistic radial seal Simulate sealing

load conditions.
condition for small
scale test.
2.
Relaxation
2.1
Loss of locking and seal capacity

during the life time
See B1.2.3, B1.3.1.4 and

B3.1
2.2
Design conditions
Establish the design

conditions based on previous
documented experiences and
the results from the
qualification.
3.
Coupling Materials
3.1
Deterioration of materials
Estimate the possible

deterioration of materials
over time to determine the
effects on the above.
(Corrosion of metallic
materials, ageing etc. of
polymer)
Wear
For numerous operations, the

maximum number should be
established.
4.
Coupling
4.1
Utilisation of internal parts with

respect to their limits. (Static and
dynamic stress, Buckling, Galling)
Verify by calculations (See

also B1.2.2)
Risk for water block of internal

parts?
Verify by assessment.
Motion/Displacement
Verify that displacement of

Verify by test.
internal parts are within their
limitations.
DET NORSKE VERITAS
Verify by strain gauges
35
September 1999
B
Tools
5.1
Tool performance
Establish possible failure

modes.
Verify by tests
Inspections after test
Establish an overview of
items to dismount, inspect
and measure after test
Inspect and measure
Test documentation
Establish an overview of
recordings, data processing of
records, inspections, and
measurements. Document
this.
C Documentation/ Main Technical correspondence

Ref
From: Manufacturer
No
Doc. No and name
Comp From Company

any
Date
Date
Ref. No and name
C
C
DET NORSKE VERITAS
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RECOMMENDED PRACTICE

MECHANICAL PIPELINE COUPLINGS

DET NORSKE VERITAS

Quality and Safety Methodology

Norsk Hydro a.s

Comments may be sent by e-mail to dtp203@dnv.com .

DET NORSKE VERITAS

Recommended Practice RP-F104

Testing (Sec. 7) deals with the test philosophy relevant for

1.4 Coupling categories

1) Joined subsea or above sea;

equal or greater than that of the pipeline, or

The pipe itself represents the key internal component of a

reduced compared to that of the pipeline

The pressure containing capacity and the bending strength of

The axial and torsion strength capacity of the coupling can

1.4.2 Installation Sensitivity

The sensitive type: No touch between pipe and seal is

1.5 Coupling grouping

1.3 Structure of Recommended Practice

This document consists of the following main elements:

Basic philosophy (Sec. 2) establishes the basic principles for

Figure 1-1 Locking principles

DET NORSKE VERITAS

Recommended Practice RP-F104

1) Uniform attachment between the pipe-wall and sleeve,

Where used in this document, the following symbols are

Furthermore, the main coupling attachment methods are

DNV Offshore Standard OS-F101: Submarine Pipeline

mechanical firm connection

mechanical strength of the coupling and

see Sec. 2.1 item 4

coupling enclosing the pipe as a sleeve.

Pipe steel cross sectional area D t t 2

Outside pipe diameter

Notations used for N:

External pipe cross section area

Other definitions are given where relevant in the text.

DET NORSKE VERITAS

Average bending radius

Recommended Practice RP-F104

2.2 Analytical methods

The qualification of couplings should, in general, be based

An analytical/numerical approach should be applied as the

DET NORSKE VERITAS

Recommended Practice RP-F104

3. Pipeline Design Basis

The installation procedures can, in particular cases, cause

The pipeline design basis shall be specified, and shall

3.2.4 Extreme Maximum & Minimum diameter

Design pressure, fluid temperature and description of

The maximum and minimum internal no touch coupling

3.2 Dimensional Tolerances

3.2.1 Welds and surface imperfections

with the quantified surface imperfection

3.2.5 Statistical Maximum & Minimum diameter

3.2.2 Line pipe