OISD-STD-141 (Revised) FOR RESTRICTED

CIRCULATION

DESIGN AND CONSTRUCTION REQUIREMENTS FOR CROSS COUNTRY HYDROCARBON PIPELINES

OISD-STD-141 First Edition, April 1990 Amended Edition, September 2001 Revised Edition, September 2003

OIL INDUSTRY SAFETY DIRECTORATE Government of India Ministry of Petroleum & Natural Gas

OISD-STD-141 Amended Edition, September 2001 Edition, September 2003 First Edition April 1990 Revised FOR RESTRICTED

CIRCULATION

DESIGN AND CONSTRUCTION REQUIREMENTS FOR CROSS COUNTRY HYDROCARBON PIPELINES

Prepared by COMMITTEE ON DESIGN AND INSPECTION OF PIPELINES

7th FLOOR, NEW DELHI HOUSE 27, BARAKHAMBA ROAD

NEW DELHI -110001

OIL INDUSTRY SAFETY DIRECTORATE

NOTE

OISD publications are prepared for use in the oil and gas industry under Ministry of Petroleum & Natural Gas. These are the property of Ministry of Petroleum &

Chemicals and shall not be reproduced or copied and loaned or exhibited to others without written consent from OISD. Though every effort has been made to assure the accuracy and reliability of the data contained in these documents. OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from their use. These documents are intended to supplement rather than replace their prevailing statutory requirements.

FOREWARD The Oil Industry in India is 100 years old. Due to various collaboration agreements, a variety of international codes, standards and practices are in vogue. Standardisation in design philosophies and operating and maintenance practices at a national level was hardly in existence. This, coupled with feed back from some serious accidents that occurred in the recent past in India and abroad, emphasised the need for the industry to review the existing state of art in designing, operating and maintaining oil and gas installations. With this in view, the then Ministry of Petroleum and Natural Gas in 1986 constituted a Safety Council assisted by Oil Industry Safety Directorate (OISD) staffed from within the industry in formulating and implementing a serious of self regulatory measures aimed at removing obsolescence, standardising and upgrading the existing standards to ensure safer operations. Accordingly OISD constituted a number of Functional Committees comprising of experts nominated from the industry to draw up standards and guidelines on various subjects. The present standard on Design and Construction Requirements for Cross Country Hydrocarbon Pipelines was prepared by the Functional Committee on Design and Inspection of Pipelines. This standard is based on the accumulated knowledge and experience of industry members and the various national and international codes and practices. This standard is meant to be used as a supplement and not as a replacement for existing codes and practices. It is hoped that the provision of this standard if implemented objectively, may go a long way to improve the safety and reduce accidents in the Oil and Gas Industry. Users are cautioned that no standard can be a substitute for the judgement of responsible and experienced engineer. Suggestions are invited from the users after it is put into practice to improve the standard further. Suggestions for amendments to this standard should be addressed to:The Coordinator, Committee on Inspection of Design and Inspection of Pipelines, Oil Industry Safety Directorate, 7th Floor, New Delhi House, 27-Barakhamba Road, New Delhi-110 001. This standard in no way supersedes the statutory regulations of Chief Controller of Explosive (CCE), Factory Inspectorate or any other Statutory body which must be followed as applicable.

COMMITTEE ON DESIGN AND INSPECTION OF PIPELINES ( First Edition April 1990 ) ------------------------------------------------------------------------------------------------------Name Organisation -------------------------------------------------------------------------------------------------------

Leader
1. Sh.V.T. Karode 2. Sh.R.A. Shanbhag ** Oil India Limited Indian Oil Corporation Limited

Members
3. Sh.Rao Rudravajala 4. Sh.S.K. Goyal 5. Sh.C.N. Char 6. Sh.E.M Bhumgara 7. Sh.R.K. Mulla 8. Sh.R.K. Dhadda 9. Sh.G.V.S. Saiprasad 10. Sh.K.K. Dutta 11. Sh.R.K. Baruah Indian Oil Corporation Limited Oil and Natural Gas Corporation Limited Oil and Natural Gas Corporation Limited Hindustan Petroleum Corporation Limited Hindustan Petroleum Corporation Limited Engineers India Limited Gas Authority of India Limited Oil India Limited Oil India Limited

Member Coordinator
12. Sh.M. Bhandari Oil Industry Safety Directorate ------------------------------------------------------------------------------------------------------In addition to the above, several other experts from the industry contributed in the preparation, review and finalisation of this document.

** (Took over as Leader w.e.f June/89 on Shri Karodes retirement from Oil India Ltd).

COMMITTEE ON DESIGN AND INSPECTION OF PIPELINES ( First Revision September 2003 ) ------------------------------------------------------------------------------------------------------Name Organisation

Leader
1. Sh.A. Sengupta Indian Oil Corporation Limited

Members
2. Sh.G.S. Wankhede 3. Sh.KBS Negi 4. Sh.S.S.Patel 5. Sh.P.K.Pal 6. Sh.C..K. Soman Bharat Petroleum Corporation Limited Bharat Petroleum Corporation Limited GAIL India Limited Indian Oil Corporation Limited Kochi Refineries Limited

Member Coordinator
7. Sh.R.N.Mittal Oil Industry Safety Directorate ------------------------------------------------------------------------------------------------------In addition to the above, several other experts from the industry contributed in the preparation, review and finalisation of this document.

DESIGN AND CONSTRUCTION REQUIREMENTS FOR

CROSS COUNTRY HYDROCARBON PIPELINES

CONTENTS Sl.No ITEM DESCRIPTION PAGE NO. 1 1 1 1 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 4 4 4 5 6

PART - I 1.0 2.0 3.0 4.0 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 5.0 5.1 5.2 6.0 7.0 7.1 7.2 7.3 7.4 7.5 7.6 7.7 INTRODUCTION SCOPE DEFINITIONS DESIGN Dynamic Effects Weight Effects Corrosion Design of Components Valves Threaded Joints Stress Values Design of Pipe supporting Elements MATERIALS Steel Materials for Sour Multiphase Service DIMENSIONAL REQUIREMENTS CONSTRUCTION, WELDING AND ASSEMBLY Location Handling, Hauling, Stringing and Storing Ditching Bends, Miters and Elbows Installation of Pipe in the Ditch Special Crossings Pump Station, Tank Farm and Terminal Construction

7.8 7.9 8.0 8.1 8.2 8.3 8.4 9.0 10.0 10.1 10.2 10.3 10.4

Storage and Working Tankage Storage Pre-Operational Stresses INSPECTION AND TESTING Type and Extent of Examination Required Testing Commissioning Record OPERATION AND MAINTENANCE PROCEDURES CORROSION CONTROL Protective Coating Cathodic Protection System Electrical Isolation Temporary Cathodic Protection System PART II

6 6 6 6 7 7 7 7 8 8 8 8 8

11.0 12.0 13.0 14.0 15.0 15.1 15.2 15.3 15.4 15.5 16.0 16.1 16.2 16.3 16.4 16.5

DESIGN PIPING SYSTEMS MATERIALS AND EQUIPMENT WELDING PIPING SYSTEM COMPONENTS AND FABRICATION DETAILS Valves and Pressure Reducing Devices Expansion and Flexibility Combined Stress Calculations Supports and Anchorage for Exposed Piping Pre-Operational Stresses DESIGN, INSTALLATION AND TESTING General Provisions Population Density Index Corrosion Allowance Cover Requirements for Pipelines Clearance Between Pipelines or Mains and other underground Structures

11 11 11 12 12 12 12 13 15 15 15 15 16 16 16 16

16.6 16.8 16.9 16.10 16.11 16.12 16.13 16.14 16.15 17.0 18.0 18.1 18.2 18.3 18.4 18.5 18.6 18.7 19.0 20.0

Casing, Requirements under Rail Roads, Highways, Roads or Streets Bends, Elbows and Miters in Steel Pipelines and Mains Miscellaneous Operations involved in the Installation of Steel Pipelines and Mains Water Crossings Crossing of / or by Utilities Testing after Construction Control and limiting of Gas Pressure Valves Pipe Book OPERATING AND MAINTENANCE PROCEDURES CORROSION CONTROL Coating Requirements Electrical Isolation Electrical Connections and Monitoring Points Electrical Interference Existing Installations Temporary Cathodic Protection System Internal Corrosion Control MISCELLANEOUS REFERENCES

16 16 17 17 18 18 20 20 21 21 21 21 21 21 22 22 22 23 23 23

DESIGN AND CONSTRUCTION REQUIREMENTS FOR CROSS COUNTRY HYDROCARBON PIPELINES

1.0

INTRODUCTION
Safety in petroleum installations and pipelines comes through continuous efforts at all stages and as such it can be ensured by observing that installations and pipelines are designed, constructed and tested as per recognised engineering standards and they are periodically inspected and maintained.

Areas not covered by 'Offshore' as defined in B 31.4 clause 400.2Definitions is defined as 'Onshore'. The definitions of 'Offshore' as per B 31.4 is reproduced hereunder for easy reference: Offshore - Areas beyond the line of ordinary high water, along that portion of the coast that is in direct contact with the open seas and beyond the line marking the seaward limit of inland coastal waters. c) ON SHORE GAS PIPELINES

2.0

SCOPE
This standard outlines the minimum requirements for design, materials, construction, assembly, inspection, testing, commissioning, operation, maintenance and safety aspects of cross country pipelines onshore, (A) transporting liquids such as crude oil, condensate, natural gasoline, natural gas liquids, and liquid petroleum products (B) transporting Natural Gas, between producer lease facilities, tank farms, natural gas processing plants, refineries, stations, terminals (marine, truck and rail) and other delivery and receiving points. For convenience 'ASME/ANSI Code B 31.4 herein after is referred' as 'B 31.4'. and 'ASME/ANSI Code B 31.8 herein after is referred' as 'B 31.8'.

Areas not covered by 'Offshore' as defined in B 31.8 clause 803.17 is defined as 'Onshore'. The definition of 'Offshore' as per B 31.8 is reproduced hereunder for easy reference: 'Offshore-Areas beyond the line of ordinary high water, along that portion of the coast that is in direct contact with the open seas and beyond the line marking the seaward limit of inland coastal waters.' d) SHALL

The word 'Shall' is used to indicate that the provision is mandatory. e) SHOULD

3.0

DEFINITIONS
a) MULTIPHASE FLUIDS

The word 'Should' is used to indicate that the provision is recommendatory as sound engineering practices. PART-I

Multiphase fluids means oil, gas or water in any combination produced from one or more oil wells or recombined oil well fluids that may have been separated in passing through treatment/processing facilities. For the purpose of this standard, multiphase fluids are considered to be low vapour pressure fluids. b) ON PIPELINES SHORE LIQUID

LIQUID PETROLEUM TRANSPORTATION SYSTEMS 4.0 DESIGN

Design of cross country pipelines onshore shall be as per ANSI/ASME B31.4. 4.1 DYNAMIC EFFECTS

Other Loadings 4.8.1 Unusual loadings such as those caused by scour, erosion, soil movement and slides, installation forces, vortex shedding and other phenomena shall also be considered and provided for in accordance with sound engineering practice. 4.2 WEIGHT EFFECTS Live Loads Weight of water during hydrostatic testing shall also be considered while designing. 4.3 CORROSION Whenever internal or external corrosion is expected during the design life of the pipeline, a suitable corrosion allowance shall be made at the design stage. 4.4 DESIGN OF COMPONENTS 4.4.1 STRAIGHT PIPE The least nominal wall thickness (tn) for steel pipe, as indicated in B 31.4 clause 404.1.1 shall not be less than the dimensions indicated in the specifications for line pipe approved by B 31.4. Further, pipe having a D/tn ratio greater than 150 shall not be used, where D = outside diameter of pipe. 4.5 VALVES Valves made of cast iron or ductile iron shall not be used. 4.6 THREADED JOINTS Threaded joints shall not be used in cross country pipelines. 4.7 STRESS VALUES Consideration shall be given to the use of lower allowable design stress if there is likelihood of repeated stress changes giving rise to fatigue conditions. 4.8 DESIGN OF PIPE SUPPORTING ELEMENTS Supports, Braces and Anchors 5.2 5.2.1 5.1.4 Wherever non integral attachments, such as pipe clamps and ring girders are used, adequate precautions shall be taken to prevent corrosion at or near the contact points. If a pipeline is designed to operate at stress level of more than 50% of the specified minimum yield strength of the pipe, all connections welded to the pipe shall be made to a separate cylindrical member which completely encircles the pipe, and this encircling member shall be welded to the pipe by continuous circumferential welds at both ends.

4.8.2

5.0
5.1 5.1.1

MATERIALS
STEEL Carbon Equivalent shall be calculated based on the formula given below: CE = C + Mn + Cr+Mo+V + Ni+Cu 6 5 15 Carbon Steels having a specified carbon content in excess of 0.32% or a carbon equivalent in excess of 0.65% shall be preheated. API-1104 shall be referred for guidance. 5.1.2 Additional test requirements shall be as per Appendix-A of Part-I of this standard for steel pipes manufactured by Electric Resistance Welding and/or Electric Induction welding. 5.1.3 Mill Hydrostatic Testing of line pipe is recommended as 90% of SMYS irrespective of grade of pipe material. The pressure hold period should be 15 sec. Ultrasonic testing for pipe skelp and weld seam is 100%. Ultrasonic testing for pipe ends is mandatory. SOUR

MATERIALS FOR MULTIPHASE SERVICE Definition

NACE Standard MR-OI-75 'Sulfide Stress Corrosion Cracking Resistant Metallic Materials for Oil Field Equipment defines limiting concentrations on hydrogen sulphide in the fluid transported' for it to be considered as sour service.

Note: While past experience has indicated this to be the accepted minimum concentration at which sulphide stress corrosion cracking may occur, the presence of other constituents in the phases making up the multiphase fluid, such as carbon dioxide in the gas and salt in the water or larger amounts of free water or gas, may cause problems to occur at lower concentrations of hydrogen sulphide. 5.2.2 General In addition to the applicable requirements of B31.4 and this standard, all materials used in sour multiphase service shall meet the following requirements. a) Pipe, valve, fittings, flanges bolting and other equipment exposed to or which are necessary to contain sour multiphase fluids may be susceptible to stress corrosion cracking and hydrogen induced stepwise cracking and thus due consideration shall be given to material selection in design. b) Materials for sour multiphase service shall conform to the requirements of NACE Standard MR01-75, 'Sulphide Stress Corrosion Cracking Resistant Metallic Material for Oil Field Equipment'. Depending upon the service and the materials involved, the Sulphide Stress Corrosion Cracking (SSCC) and Hydrogen Induced Cracking (HIC) tests should be conducted as per NACE standards referred in Clause 20.0 of this standard. The acceptance criteria shall be based on current established industry practice. c) Pressure containing components (excluding pipe) intended for sour multiphase service shall be fully identified with a permanent marking. 5.2.3 Pipes made of cast iron, ductile iron, bronze and other copper based materials shall not be used in sour multiphase service.

7.0
7.1

CONSTRUCTION, WELDING AND ASSEMBLY

LOCATION The location of a new underground pipeline, when running parallel to an existing underground pipeline, should be at a minimum clear distance of 5.0 metres from the existing underground pipeline when heavy conventional construction equipment is excepted to be utilized. This distance may be reduced after careful assessment of construction methodologies so that it does not result in unsafe conditions during construction. In any case the minimum clear distance shall not be less than 3.0 metres. These areas shall be distinctly identified on ground during construction. No pipeline should be located within 15.0 metres of any private dwelling or any industrial building or place of public assembly in which persons work, congregate or assemble, unless it is provided with at least 300 mm of cover in addition to that provided in Table 7.3.3 of this standard.

7.2

HANDLING, HAULING, STRINGING AND STORING Pipe shall not be strung along the right of way in rocky areas where blasting may be required, until all blasting is complete and the area cleared of all debris. Material other than line pipe shall not be strung on the right of way but shall be transported to site for use only at the time of installation.

7.3
7.3.1

DITCHING
The width of trench shall be such that a minimum clear distance of 200mm for trench in normal soil and 300mm for trench in rock is maintained between edge of pipe and the trench wall at the bottom of trench. Pipelines shall be buried below ground level, unless construction above ground is found to be desirable for exceptional technical, economic or topographical reasons. Minimum cover for Buried Pipelines

7.3.2

6.0

DIMENSIONAL REQUIREMENTS
All provisions of B 31.4 Chapter IV shall apply. 7.3.3

The minimum cover shall be as per table 7.3.3 given below. TABLE 7.3.3 Minimum Cover for Buried Pipelines ________________________________ Location Minimum Cover in metre ________________________________ Industrial, Commercial 1.0 (2) and Residential Areas Stream, Canal and other Minor water crossings Drainage ditches at Roadways and railroads Rocky Areas Uncased/Cased Road Crossings Railroad Crossings Other Areas 1.5 (4) 1.0 1.0 (2) 1.2 (3) 7.4.4 1.4 (3) 1.0 (2) 7.5

section shall permit easy jointing. Tangents approximately 1 metre in length shall be provided on both ends of cold bends. 7.4.2 Pipes with longitudinal welds shall be bent in such a way that weld lies in the plane passing through neutral axis of the bend which shall be installed positioning the longitudinal weld in the upper quadrants. BENDS MADE FROM PIPE

7.4.3

The minimum radius of field cold bends shall be as follows: ________________________________ Nominal Pipe Minimum Radius of size In Bend in Pipe Diameter ________________________________ NPS 12 and smaller 21D NPS 14 u/i 18 30D NPS 20 and larger 40D MITERED BENDS A mitered bend is not permitted with the exception of deflections upto 3 degrees that are caused by misalignment. INSTALLATION OF PIPE IN THE DITCH Before lowering operations are commenced, particular attention shall be paid to the suitability of the trench to allow the pipeline to be lowered without the coating being damaged and to give a reasonably even support to the pipeline. When already coated pipes are being lowered, a complete check of the pipe coating and field joint coating shall be carried out and all damages repaired. Wherever pipeline is laid under tension as a result of an assembly error (for example incorrect positioning of bends, either horizontal or vertical), the trench shall be rectified or in exceptional cases a new assembly shall be carried out so that it fits the excavation and the laying bed. Care must be taken that during laying, the deformation caused during the raising of the pipe from the support does not exceed the values for the minimum allowable radius of elastic

(1) The above mentioned minimum cover requirements shall be valid for all class locations. (2) Minimum depth of cover shall be measured from the top of pipe coating to the top of undisturbed surface of the soil, or top of graded working strip, whichever is lower. Fill material in working strip shall not be considered to add to the depth of cover. (3) Cover shall be measured from the top of road or top of rail, as the case may be. (4) In case of rivers/water bodies, which are prone to scour and erosion, adequate safe cover (minimum 1.5 metre) shall be provided below the predicted scour profile expected during the life time of the pipeline. 7.4 BENDS, MITERS AND ELBOWS Bends made from pipe 7.4.1 The ends of each bent length shall be straight and not involved any way in the bending. The length of the straight

curvature, so as to keep the stresses in the steel pipe and on the coating within safe limits. In laying parallel pipelines in the same trench, the minimum clear distances between the pipelines shall be 500 mm. 7.6 7.6.1 SPECIAL CROSSINGS Water crossings Special considerations shall be required for submerged crossings which are characterized by their perennial nature, meandering course, steep and potentially erodable banks, potentially scouring bed, large erodable flood plain and wide water course (high water mark to high water mark) both during the design and installation of such crossings. For river crossings such as those described and established above the following additional requirements are to be considered. a) Hydrological and geotechnical surveys to establish the river bed and water current profiles to predict the behaviour of the river with respect to change of course, scour of bed and erosion of banks and to obtain all other parameters related to design and installation of such crossings. b) The pipeline at such crossings shall be installed with extra depth of cover. The cover provided shall be adequate to prevent exposure of the pipeline for the entire design life of the pipeline. c) To ensure the stability of the underwater pipeline, it may be necessary to add weight to sink and hold the pipeline in position. d) A heavier wall thickness pipe shall be provided for the river crossing section. e) A detailed stress analysis for the pipe section for river crossings should be carried out, taking into consideration the effect of all loads during laying and it shall be ensured that the stresses remain within permissible limits in accordance with B 31.4. 7.6.2

f) Whenever considered desirable, the section of the pipeline corresponding to the river crossing should before installation be subjected to hydrostatic pre-testing. However, the complete pipeline corresponding to river crossing shall be tested after installation. Crossing of or by Utilities a) A minimum clearance of 300mm shall be maintained at the point of crossing and the utility or pipeline shall be installed at a uniform depth for the full width of the right of way. Where it is not practicable to obtain the above mentioned clearance, special design and construction shall be used. b) A clearance sufficiently large to avoid electrical fault current interference shall be maintained between the pipeline and the grounding facilities of electrical transmission lines. c) Interference with, or from, other systems through the application of cathodic protection shall be dealt by mutual action of the parties involved. d) When laid parallel to, along or near underground power and / or communication cables, conductors or conduit, underground pipes shall maintain a vertical clearance of at least 300 mm. Where these clearances cannot be maintained, extra precaution shall be taken to ensure the maximum possible clearance and to prevent future contact. If pipelines and communication and / or power utilities share the same trench, the above clearance shall be maintained with the pipeline preferably at a lower level. e) A minimum separation of 3.0 metre should be maintained between pipeline and transmission tower footings, ground cables and counter poise. Regardless of separation, consideration should always be given to lightning fault current protection of pipelines and safety of personnel. 7.6.3 All crossings shall be made in such a manner that the angle between the centerline of the railway, highway, river, stream, canal or utility being crossed and the centerline of the pipeline shall

be as close as possible to 90 degree but in no case less than 45 degree . 7.7 7.7.1 PUMP STATION, TANK FARM AND TERMINAL CONSTRUCTION Location Minimum distances from property lines and road allowance limits to buildings and equipment etc. shall meet the requirements of OISD Standard 118 "Layouts for Oil and Gas Installations". 7.8 STORAGE AND WORKING TANKAGE STORAGE Underground Storage Prior to design and construction of an underground storage chamber, an engineering and geological investigation shall be carried out to determine the feasibility of such a system at the proposed site. Such chambers shall be constructed and operated in accordance with GPA Publication 8175, Method for Underground Storage of National Gas Liquids 7.9 PRE-OPERATIONAL STRESSES It is desirable to limit stresses during pre-operational manipulation of the pipe so as to avoid damage that might impair the operability of the line. The designer shall ensure that preoperational stresses are controlled and that they are non-injurious to the pipe. Consideration shall be given to, but not restricted to, the effect of the following pre-operational loads: a) Transportation and stockpiling of the pipe; b) Stringing, coating wrapping, and laying.; c) Backfilling; and 8.1.2 8.1.1

soils).

8.0
8.1

INSPECTION AND TESTING

TYPE AND EXTENT EXAMINATION REQUIRED Construction Field pipeline coating shall be applied on a properly prepared surface and visually inspected during application. Any cutting or removal of the coating shall be promptly and carefully repaired. Yard-coated pipe shall be examined after field bending to ensure that the quality of the coating has not been impaired. Additional precautions such as double coating, rock shield, selected backfill, and ditch padding shall be taken where conditions are such that damage to the pipe coating could occur. If moisture is present on the surface of the pipe, no coating materials shall be applied. Unless special procedures can be taken, no coating shall be applied when the ambient temperature might have a detrimental effect on the coating either during or after application. TESTING A gauging pig shall be passed through the pipeline to prove the internal diameter of the entire line. The gauging plate shall have a diameter of 95% of the internal diameter of the pipeline. All sections which have been previously hydrostatically tested viz. road/rail crossings and river crossings shall be retested alongwith the completed mainline sections. Water used for testing should be dozed with suitable corrosion inhibitor, if required. OF

8.1.3

8.1.4

8.1.5

8.2 8.2.1

8.2.2

d) Loads imparted by construction traffic; e) Field bending; 8.2.3

Test Pressure Hydrostatic Testing Pressure Piping of Internal

f) hydrostatic test pressure loads (particularly when the pipeline is constructed as an above ground installation or is buried in unstable

The test pressure shall be decided as

per B31.4. The duration of hydrostatic proof test shall be minimum 24 hours. 8.2.4 Acceptance of Test The test is successful when the pipeline has withstood the strength and leak tests and during the test period there is no observable drop in pressure that cannot be accounted for by temperature changes. 8.2.5 Termination of Testing The pipeline shall be slowly depressurized at a moderate and constant rate. During dewatering, care shall be taken to properly dispose the discharging water in order to avoid pollution, damages to fields under cultivation and/or existing structures and interference with the traffic. 8.2.6 Pre- tested Pipe Pipe used for making repairs shall be pre-tested to a pressure equal to or greater than the original pipeline strength test pressure. 8.2.7 Preservation of Pipeline If the pipeline is to be preserved for a specified duration before it can be commissioned, the pipeline shall be completely filled with water with sufficient quantities of corrosion inhibitors depending upon the quality of water and the period of preservation and at a suitable pressure. 8.3 8.3.1 COMMISSIONING Commissioning shall consist of displacing the hydrostatic test water from the pipeline by pumping in the liquid to be transported. Batching pigs or spheres shall be used not only to minimize mixing at the interface but also to enable the progress of the interface to be followed. In cases where the water has to be cleared from the pipeline before commissioning because of possible chemical or physical action between the water and the liquid to be transported, the pipeline shall be first drained and then dried as thoroughly as possible. After drying, the pipeline shall be filled with the liquid. Care shall 8.4

be taken to clear pockets of water from valves and fittings. RECORD Pipe Book A pipe and welding book shall be maintained for all projects. The purpose of the pipe book shall be to indicate and maintain as a permanent record the exact position in the pipeline of each pipe length and each pipeline material like valves, scraper traps, bends, flanges, and other fittings installed in the project. Each item shall be recorded by its identification number. Location of each weld including weld number, welder number, type of welding and electrode, weld treatment and details of equipment used for radiography shall be recorded in the pipe book.

9.0

OPERATION AND MAINTENANCE PROCEDURES

All provisions of B 31.4-Chapter-VII and OISD-STD-138 shall apply.

10.0
10.1

CORROSION CONTROL
PROTECTIVE COATING a) Coatings shall electrically isolate the external surface of the piping system from the environment. b) All joints, fittings, repairs and tie-ins shall be coated with a material compatible with the existing coating.

10.2 CATHODIC PROTECTION SYSTEM a) Existing Bare Pipelines Systems Investigation shall be made to determine the extent or effect, of corrosion on existing bare pipeline systems. When these investigations indicate that continuing corrosion will create a hazard, corrosion control measures or other remedial action shall be undertaken. b) Cathodically Protected Pipeline Systems Temporarily Out of service Cathodic Protection system shall be maintained on any pipeline that is temporarily out of service.

8.3.2

10.3

ELECTRICAL ISOLATION Whereas such insulating devices are installed, they shall be properly rated for temperature, pressure, electrical properties, and shall be resistant to the commodity carried in the pipeline systems.

10.4

TEMPORARY CATHODIC PROTECTION SYSTEM When considered necessary a temporary cathodic protection system with sacrificial anodes shall be installed to ensure adequate protection of pipeline from external corrosion from the time the pipeline is laid in the trench till the permanent cathodic protection system is commissioned. The temporary CP system shall preferably be installed simultaneously keeping pace with the pipeline laying / installation work and shall be monitored periodically.

a) Selection of Mandrel The reverse bend test shall be carried out with a mandrel, whose radius(R), width(A) shall be calculated for any combination of diameter, wall thickness and grade with the formula. A = 2R = 1.4 (D-t) t ------------e(D-2t)-1.4t -t

10.5

Safety appliances shall be provided against lightning, stray current interference from foreign objects at HT pipeline crossings.

where, D - Outside diameter of pipe t - Wall thickness of pipe 1.4 - Peaking factor e - Strain Minimum values of 'e' shall be as follows: ---------------------------------------------------Grade of Steel Min 'e' value ---------------------------------------------------ASTM A53 B 0.1425 ASTM A 135 B 0.1425 API 5L B 0.1425 API 5L X-42 0.1375 API 5L X-46 0.1325 API 5L X-52 0.1275 API 5L X- 56 0.1175 API 5L X- 60 0.1125 API 5L X- 65 0.1100 API 5L X- 70 0.1025 API 5L X- 80 0.0900 ---------------------------------------------------b) Procedure The mandrel is to be plugged into the specimen, with the weld in contact with mandrel, to such a depth that the angle of engagement between mandrel and specimen reaches 600 (see Fig. B1). If the combination of diameter and wall thickness of pipe, and radius of

APPENDIX - A ADDITIONAL REQUIREMENTS FOR ELECTRIC RESISTANCE/ELECTRIC INDUCTION WELDED LINE PIPE
B.1 Reverse Bend Tests Reverse bend tests shall be performed on the pipe piece cut from the crop end from the front end of the first length and the back end of the last length produced from each coil. The specimen shall be 100mm to 115mm long and shall be reverse bend tested in accordance with procedure given below and Figure B.1.

mandrel is such that the angle of engagement does not reach 600, the mandrel shall be plugged into the specimen until opposite walls of the specimen meet. c) Acceptance Criteria A specimen which fractures completely prior to the specified engagement of mandrel and specimen, or which reveals cracks and ruptures in the weld or heat affected zone longer than 4mm, shall be rejected. Cracks less than 6mm long at the edges of the specimen shall not be cause for rejection. B.2 Micrographic and Hardness Examination A test specimen shall be taken across

the longitudinal weld from one length of finished pipe from each lot of maximum 50 lengths from the same heat manufactured from the same process. These specimens shall be polished and etched for micro-examinations. The examinations shall provide evidence that heat treatment of weld zone is adequate and there is no untempered martensite left. The Manufacturer shall make hardness measurements on each specimen as indicated in Fig. B.2 in accordance with ASTM E-32. The maximum difference in hardness between base material and any reading taken in the heat affected zone shall be less than 80 points Vicker's HV10.

PART-II GAS TRANSPORTATION SYSTEMS

11.0 DESIGN
Design of cross country pipelines onshore shall be as per ANSI/ASME B31.8. temperature shall be taken as the lowest expected operating pipe or metal temperature when the hoop stress exceeds 50 MPa (7000 psi), having due regard to past recorded temperature data and the minimum gas temperature that may occur. The minimum design temperature shall take into account the effect of lower air or ground temperatures in the area. b) The maximum design temperature shall be taken as the highest expected operating pipe or metal temperature, having due regard to past recorded temperature data and the possibilities of higher temperatures occurring. 13.3 MATERIAL SPECIFICATIONS

12.0
12.1

PIPING SYSTEMS
The Pipe wall thickness less than 6.4 mm should not be used for cross country pipelines in the city limits. Pipe diameter 4 and above shall be used for cross country pipelines. All cross country pipelines shall be piggable.

12.2 12.3

13.0
13.1

MATERIALS AND EQUIPMENT

When the maximum design temperature exceeds 120 deg.C (250 deg. F), particular attention shall be given to the tensile properties of the material to ensure that the derating for temperature is adequate. OPERATING CONDITIONS, TEMPERATURE AND NOTCH TOUGHNESS REQUIREMENTS

13.3.1 Carbon Equivalent Carbon Equivalent shall be calculated based on the formula given below: CE = C + Mn + Cr+Mo+V + Ni+Cu 6 5 15 Carbon Steels having a specified carbon content in excess of 0.32% or a carbon equivalent in excess of 0.65% shall be preheated. API-1104 shall be referred for guidance. 13.3.2 If steel pipe is intended to be heated during fabrication and/or installation, the effect of the time-temperature relationship on the mechanical properties of the pipe shall be determined and taken into consideration. 13.3.3 Additional test requirements shall be specified as per Standards / Guidelines mentioned in Appendix-A, Part-I of this standard for steel pipes manufactured by Electric Resistance Welding and/or Electric Induction Welding. 13.3.4 Mill Hydrostatic Testing of line pipe is recommended as 90% of SMYS irrespective of grade of pipe material. The pressure hold period should be 15 sec.

13.2

13.2.1 For steel pipes smaller than 2" NPS and steel valves, fittings and flanges smaller than 2" NPS, proven notch toughness properties are not mandatory. 13.2.2 For steel pipes and associated steel components of size 2" NPS and larger, Notch toughness values shall be determined to provide protection against fracture initiation and propagation. Notch toughness valves (minimum absorbed energy valves) shall be specified based on the design operating stress and the minimum design temperature. 13.2.3 The minimum and maximum design temperatures shall be determined as follows: a) The minimum design

13.3.5 Ultrasonic testing for pipe skelp and weld seam is 100%. Ultrasonic testing for pipe ends is mandatory. 13.4 REQUIREMENTS FOR SOUR GAS SERVICE

criteria shall be based on current established industry practices. d) Pressure containing components (excluding pipes) intended for sour gas service shall be fully identified with a permanent marking. e) Cast iron line pipe shall not be used to convey sour gas.

13.4.1 Definition NACE standard MR-01-75 "Sulphide Stress Corrosion Cracking Resistant Metallic Material for Oil Field Equipment" defines specific conditions, which a gaseous hydrocarbon shall be considered to be sour. Note: While the limiting conditions defined in NACE standard MR-01-75 for considering gaseous hydrocarbons as sour is the normally accepted minimum concentration of hydrogen sulphide at which material problems occur, the presence of other constituents in the gas stream, such as CO2 and Salts in water, may cause problems at lower concentrations of hydrogen sulphide. 13.4.2 General a) In addition to the applicable requirements of B 31.8 and this standard, all materials used in sour gas service shall also meet the following requirements. b) Pipe, valves, fittings, flanges, bolting and other equipment exposed to or which are necessary to contain sour gas may be susceptible to Sulphide Stress corrosion cracking and hydrogen induced step-wise cracking and thus due consideration shall be given to material selection in design. c) All materials used in sour gas service shall conform to the material requirements of NACE standard MR01-75, "Sulphide Stress Corrosion Cracking Resistant Metallic Material for Oil Field Equipment". Depending upon the service and the materials involved, the Sulphide Stress Corrosion Cracking (SSCC) and Hydrogen Induced Cracking (HIC) tests should be conducted as per NACE standards mentioned in Clause 20.0 of this standard. The acceptance 15.1

14.0

WELDING
Carbon equivalent (CE) wherever referred in this chapter, shall be calculated based on the following formula: CE = C + Mn + Cr+Mo+V + Ni+Cu 6 5 15 Carbon Steels having a specified carbon content in excess of 0.32% or a carbon equivalent in excess of 0.65% shall be preheated. API-1104 shall be referred for guidance.

15.0

PIPING SYSTEM COMPONENTS AND FABRICATION DETAILS

VALVES AND REDUCING DEVICES PRESSURE

Valves made of cast iron or ductile iron shall not be used in gas piping systems. 15.2 EXPANSION AND FLEXIBILITY

15.2.1 This section is applicable to both above ground and buried piping and covers all classes of materials permitted by this standard. Formal calculations shall be required where reasonable doubt exists as to the adequate flexibility of the piping. Note : For the purpose of this standard, 'unrestrained' means that the pipe is able to strain along its length, move laterally, or both. Pipe that does not meet both of the above requirements is referred to as 'restrained'. Typically, long straight lengths of buried pipe and above ground pipe on closely spaced rigid supports are classified as restrained, whereas buried pipelines adjacent to bends or unanchored end caps could be regarded as restrained or

unrestrained, depending on specific circumstances. 15.2.2 EXPANSION AND FLEXIBILITY a) Expansion calculations are necessary for buried lines if significant temperature changes are expected. Thermal expansion of buried lines may cause movement at points where the line terminates, changes in direction, or changes in size. Unless such movements are restrained by suitable anchors, the necessary flexibility shall be provided. b) Means of providing Flexibility If expansion is not absorbed by direct axial compression of the pipe, flexibility shall be provided by the use of bends, loops, or offsets or provision shall be made to absorb thermal strains by expansion joints or couplings of the slip joint, ball joint, or bellows type. If expansion joints are used, anchors or ties of sufficient strength and rigidity shall be installed to provide for end forces due to fluid pressure and other causes. 15.3 COMBINED STRESS CALCULATIONS

(c) Differential movements;

support

(d) Self-weight and gravity dead loads; (e) Static wind loads and static fluid loads. ii) In addition to the requirements of Clause 15.3.2(i) above, consideration shall be given, where applicable, to the service conditions to which the pipe and support system are to be subjected. Consideration shall also be given to, but not necessarily limited to the effects of the following additional loadings: (a) (b) (c) Overburden loads; Live loads; Buoyancy;

(d) Dynamic and seismic loads: Seismic load consideration for earthquake prone areas should be taken after proper seismic survey to determine liquefaction factor of soil. The pipeline cover will be decided considering the above factor. (e) Cyclic and vibratory loads including the effect of Stress Intensification. Factors on the fatigue life of components; (f) Internal pressure fluctuations;

15.3.1 General In addition to satisfying the requirements of clause 841 of B 31.8, it may be necessary to calculate the longitudinal, axial, and bending stresses, the torsional stresses, the hoop stresses, the stress interactions and the reactions at significant points in the system. In calculating these stresses and reactions and the effects of various loadings on the piping the designer shall use established fundamental analysis methods. 15.3.2 Loading Considerations

(g) External hydrostatic pressure (including collapse, wave loadings and all significant fluid loads to which a submerged line might be submitted); (h) Geotechnical loads (including slides, differential settlement, loss of support, and thermal effect of the pipeline on soil properties). 15.3.3 Stress Values

i) Consideration shall be given to the stresses and reactions caused by, but not necessarily limited to the following loadings:(a) Internal pressure; expansion and

a) General There are fundamental differences in loading conditions for the buried, or similarly restrained positions of the piping and the above ground portions not subject to substantial axial restraint. Therefore, different limits on allowable longitudinal expansion

(b) Thermal contraction;

stresses are necessary. b) Restrained Lines The net longitudinal compressive stress due to the combined effects of temperature rise and fluid pressure shall be computed from the equation: SL = Ea (T2-T1) - v Sh in which, SL = The longitudinal compressive stress, psi(MPa) Sh = Hoop stress due to internal fluid pressure, psi (MPa) T1 = Temperature at time installation degrees F(degrees C) T2 = Maximum or operating temperature F(degrees C) of

SE = Sq. Root of (Sb2 + St2 ) Where, SE = Stress due to expansion. Sb = Sq. Root of{( i1 M1)2 + ( i0 M0)2}/Z =equivalent bending stress, psi (MPa) St = Mt/2Z = torsional stress, psi(MPa) M1 = Bending moment in plane of member (for members having significant orientation, such as elbows or tees, for the latter the moments in the header and branch portions are to be considered separately) in.lb. (N.m) M0 = bending moment out of, or transverse,to plane of member, in lb. (N.m) Mt = torsional moment, in lb. (N.m) ii = stress intensification factor under bending in plane of member (B 31.8 Appendix E) io = stress intensification factor under belonging out of, or transverse to, plane of member (B 31.8 Appendix E) Z = Section modulus inch 3(mm3) of pipe,

minimum degrees

E = Modulus of Elasticity of steel, psi (MPa) a = Linear coefficient of thermal expansion, inch per inch per degree F (mm per mm per degree C) v = Poisson's ratio = 0.30 for steel

Note that the net longitudinal stress becomes compressive for moderate increases of T2 and that according to the commonly used maximum shear theory of failure, this compressive stress adds directly to the hoop stress to increase the equivalent tensile stress available to cause yielding. This equivalent tensile stress shall not be allowed to exceed 90 per cent of the specified minimum yield strength of the pipe, calculated for nominal pipe wall thickness. Beam bending stresses shall be included in the longitudinal stress for those portions of the restrained line which are supposed above ground. c) Unrestrained Lines Stresses due to expansion for those portions on the piping without substantial axial restrain shall be combined in accordance with the following equation:

The maximum computed expansion stress range, SE without regard for fluid pressure stress, based on 100 per cent of the expansion, with modulus of elasticity for the cold condition, shall not exceed 0.72 times the specified minimum yield strength of the pipe. The total of the following shall not exceed the specified minimum yield strength, S. a) the combined stress due to expansion, SE. b) the stress. longitudinal pressure

c) the longitudinal bending stress due to external loads, such as weight of pipe and contents, wind etc. The sum of the longitudinal stresses

due to pressure, weight, and other sustained external loadings shall not exceed 0.75 time the allowable stress in the hot condition. The sum of the longitudinal stresses produced by pressure, live and dead loads, and those produced by occasional loads, such as wind or earthquake, shall not exceed 80 per cent of the specified minimum yield strength of the pipe. It is not necessary to consider wind and earthquake as occurring concurrently. Stresses due to test conditions are not subject to the above limitations. It is not necessary to consider other occasional loads, such as wind and earthquake, as occurring concurrently with the live, dead and test loads existing at the time of test. 15.4 SUPPORTS AND ANCHORAGE FOR EXPOSED PIPING Attachment of supports on Anchors Due consideration shall be given to the effect of such attachments on possible fatigue failures and local stress concentrations. 15.5 PRE-OPERATIONAL STRESSES It is desirable to limit stresses during pre-operational manipulation of the pipe so as to avoid damage that might impair the operability of the line. The designer shall ensure that preoperational stresses are controlled and that they are non-injurious to the pipe. Consideration shall be given to, but not restricted to, the effect of the following pre-operational loads: a) Transportation and stockpiling of the pipe; b) Stringing, coating and wrapping, and laying; c) Backfilling; d) Loads imparted by construction traffic; e) Field bending; f) hydrostatic test pressure loads (particularly when the pipeline is 16.5

constructed as an above grade installation or is buried in unstable soils).

16.0
16.1

DESIGN, INSTALLATION AND TESTING

GENERAL PROVISIONS The selection of design for pipeline system shall be based on the following evaluation of the properties and required flow rate of the fluid to be transported, together with the environment in which the pipeline is to be installed. a) Sweet or sour natural gas, single or multiphase flow conditions, vapour phase LPG. b) Operating temperatures. pressures and

c) Gathering transmission system, system, or service lines. d) 16.2

system, distribution

Onshore or offshore pipeline.

POPULATION DENSITY INDEX A Class 4 location ends 220 metre from the nearest building with 4 or more stories above ground.

16.3

CORROSION ALLOWANCE Whenever internal or external corrosion is expected during the design life of the pipeline, a suitable corrosion allowance shall be made at the design stage.

16.4

COVER REQUIREMENTS PIPELINES Refer Table requirements. 7.3.3 for

FOR cover

CLEARANCE BETWEEN PIPELINES OR MAINS AND OTHER UNDERGROUND STRUCTURES

16.5.1 In laying parallel pipelines in the same trench, the minimum clear distances between the pipelines shall be 500 mm.

16.5.2 The location of a new underground pipeline, when running parallel to an existing underground pipeline should be at a minimum clear distance of 5.0 metre from the existing underground pipeline when heavy conventional construction equipment is expected to be utilized. This distance may be reduced after a careful assessment of construction methodologies, which do not result in unsafe conditions during construction. In any case the minimum clear distance shall not be less than 3.0 meter. These areas shall be distinctly identified on ground during construction. No pipeline should be located within 15.0 metre of any private dwelling, or any industrial building or a place of public assembly in which persons work, congregate or assemble, unless it is provided with atleast 300 mm of cover in addition to that provided in clause 16.4 of this standard. 16.6 CASING, REQUIREMENTS UNDER RAILROADS, HIGHWAYS, ROADS, OR STREETS Pipeline, casing pipe and vent pipes shall be at least 1.2 metre away (vertically) from aerial electrical wires and shall be suitably insulated from underground conduits carrying electric wires on railway land. 16.7 Design and construction of gas pipelines crossing Railroads, Highways, Roads or Streets shall be done in accordance with the provisions of "Recommended Practice for Liquid Petroleum Pipelines Crossing Railroads and Highways" API RP 1102 and applicable clauses of B31.8 and this standard. BENDS, ELBOWS AND MITERS IN STEEL PIPELINES AND MAINS The minimum radius of field cold bends shall be as follows: _______________________________ Normal Pipe Minimum Radius of Size (in) Bending in Pipe Diameters _______________________________ NPS 12 and smaller 21 D NPS 14 u/i 18 30 D NPS 20 and larger 40 D _______________________________

16.8.1 The ends of each bent length shall be straight and not involved anyway in the bending. The length of the straight section shall permit easy jointing. Tangents approximately 1 metre in length shall be provided on both ends of cold bends. A field bend shall not be made within two pipe diameters of a field weld. Tangent lengths should not be reduced in the field. 16.8.2 Pipes with longitudinal welds shall be bent in such a way lies in the plane passing through neutral axis of the bend which shall be installed positioning the longitudinal weld in the upper quadrants. 16.8.3 A mitered bend is not permitted with the exception of deflections upto 3 degrees that are caused by misalignment. 16.8.4 Field-cut segments of elbows NPS 12" and larger are not recommended. 16.9 MISCELLANEOUS OPERATIONS INVOLVED IN THE INSTALLATION OF STEEL PIPELINES AND MAINS

16.9.1 Handling, Hauling, and Stringing Pipe shall not be strung on the Rightof-Way in rocky areas where blasting may be required, until all blasting is complete and the area cleared of all debris. Material other than line pipe shall not be strung on the Right-of-way but shall be transported to site for use only at the time of installation. 16.9.2 Installation of Pipe in the Ditch Pipelines shall be buried below ground level, unless construction above ground is found to be desirable for exceptional technical, economic or topographical reasons. Before lowering operations are commenced, particular attention shall be paid to the suitability of the trench to allow the pipeline to be lowered without the coating being damaged and to give a reasonably even support to the pipeline. When already coated pipes are being lowered, a complete check of the pipe

16.8

coating and field joint coating shall be carried out and all damages repaired. Wherever pipeline is laid under tension as a result of an assembly error (for example, incorrect positioning of bends, either horizontal or vertical), the trench shall be rectified or in exceptional cases a new assembly shall be carried out so that it fits the excavation and the laying bed. Care must be taken that the deformation caused during the raising of the pipe from the supports does not exceed the valves for the minimum allowable radius of elastic curvature, so as to keep the stresses on the steel pipe and on the coating within safe limits. The width of trench shall be such that a minimum clear distance of 200mm for trench in normal soil and 300mm for trench in rock is maintained between edge of pipe and the trench wall at the bottom of trench.

(c)

To ensure the stability of the underwater pipeline, it may be necessary to add weight to sink and hold the pipeline in position. A heavier wall thickness pipe shall be provided for a river crossing section. A detailed stress analysis for the pipe section for river crossings should be necessary taking into consideration the effect of all loads during laying and it shall be ensured that the stresses remain within permissible limits in accordance with B 31.8 and this standard. Whenever considered desirable, the section of the pipeline corresponding to the river crossing should, before installation, be subjected to hydrostatic pretesting. However, the complete pipeline corresponding to river crossing shall be tested after installation. CROSSING OF / OR BY UTILITIES

(d) (e)

(f)

16.11 16.10 WATER CROSSINGS Special considerations shall be required for submerged crossing by pipelines of rivers which are characterized by their perennial nature, meandering course, steep and potentially erodable banks, potentially scouring bed, large erodable flood plain and wide water course (high water mark to high water mark) both during the design and installation of such crossings: For river crossings such as those described and established as above, the following requirements are to be considered: (a) Hydrological and geotechnical surveys to establish the river bed and water current profiles, to predict the behaviour of the river with respect to change of course, scour of bed and erosion of banks and to obtain all other parameters related to design and installation of such crossings. The pipeline at such crossings shall be installed with extra depth of cover. The cover provided shall be adequate to prevent exposure of the pipeline for the entire design life of the pipeline.

16.11.1 A minimum clearance of 300mm shall be maintained at the point of crossing and the utility or pipeline shall be installed at a uniform depth for the full width of the right-of-way, provided that, where it is not practicable to obtain the above mentioned clearance, special design and construction shall be used. 16.11.2 A clearance sufficiently large to avoid electrical fault current interference shall be maintained between the pipeline and the grounding facilities of electrical transmission lines. 16.11.3 Interference with, or from, other systems through the application of Cathodic Protection shall be dealt with by mutual action of the parties involved. 16.11.4 When laid parallel to along or near underground power and/or communication cables, conductors, or conduit, underground pipes shall, maintain a vertical clearance of at least 300mm. Where these clearances cannot be maintained, extra precaution shall be taken to ensure the maximum possible clearance and to prevent future

(b)

contact. If pipelines and communication and/or power utilities share the same trench, the above clearance shall be maintained with the pipeline preferably at a lower level. 16.11.5 A minimum separation of 3.0 metre should be maintained between pipeline and transmission tower footings, ground cables and counter poise. Regardless of separation consideration should always be given to lightning fault current protection of pipelines and safety of personnel. 16.11 6 All crossings shall be made in such a manner that the angle between the centreline of the railway, highway, river, stream, canal or utility being crossed and the centreline of the pipeline shall be as close as possible to 90 deg. but in no case less than 45 deg. 16.12 TESTING AFTER CONSTRUCTION

offshore platform piping shall be maintained for a minimum period of 4 hours, during which time the piping shall be inspected for leaks. All sections, which have been previously hydrostatically tested viz. road/rail crossings and river crossings, shall be retested along with the completed mainline sections. A guaging pig shall be passed through the pipeline to prove the internal diameter of the entire line, the guaging plate having a diameter of 95% of the internal diameter of the pipeline. When water is used as the test medium, inhibited water, i.e. water to which suitable doses of corrosion inhibitors are added depending upon quality of water, shall be used. b) Pipelines and mains located in class 1 and class 2 location shall be tested with air, gas or water to at least 1.25 times the maximum operating pressure. Testing, wherever practicable, shall be by means of water rather than a gaseous medium. Where a gaseous medium is used, the test pressure shall not exceed 1.25 times the maximum operating pressure. Sour gas shall not be used as a test medium. c) Compressor station, regulator station and measuring station gas piping, including the piping connecting the station to valving employed for isolating the station from the pipeline and designed in accordance with Type-C construction (Design factor = 0.5) shall be tested to atleast class 3 location test requirements. d) Where testing of offshore platform gas piping and pipe riser cannot be accomplished separately from the main offshore pipeline, the piping components shall be pretested to atleast 1.4 times the maximum operating pressure, provided that all final welds are inspected in accordance with the provisions of B 31.8 and all such piping is retested with the main offshore pipeline to class 1 location test requirements. e) Test Requirements for Pipelines and Mains to Operate at Hoop

16.12.1 General Provisions a) All Pipelines, mains, and service lines shall be tested in place after construction, except as provided for in (b) below. b) Tie-ins For pipelines intended to operate at hoop stresses of 30% or more of the specified minimum yield strength pretested pipe shall be used in tie-in sections and for those sections where in-place testing is not practicable. 16.12.2Test Required to Prove Strength of Pipelines and Mains to Operate at Hoop Stresses of 30% or More of the Specified Minimum Yield Strength of the Pipe: a) All test assemblies used in testing shall be fabricated and installed in accordance with provisions of B 31.8 covering permanent assemblies and fabrications. For all buried and submerged piping, the test pressure shall be maintained for a period of 24 hours after temperature stabilization and stabilization of surges from pressurizing operations. The test pressure for above ground piping and

Stresses of 30% or More of the Specified Minimum Yield Strength of the Pipe

GENERAL NOTES: mop = Maximum operating pressure (not necessarily the maximum allowable operating pressure) dp = design pressure tp = test pressure This table brings out the relationship between test pressures and maximum allowable operating pressures subsequent to the test. If an operating company decides that the maximum operating pressure will be less than the design pressure, a corresponding reduction in prescribed test pressure may be made as indicated in the pressure Test Prescribed, Minimum, column. However, if this reduced test pressure is used, the Maximum operating pressure cannot later be raised to design pressure without retesting the line to the test pressure prescribed in the Pressure Test Prescribed. f) In such cases an air test to 1.25 times the maximum operating pressure shall be made and the limitations on operating pressure imposed by Table 16.12.2.5 of this standard do not apply. g) Records

The operating company shall maintain in its file for the useful life of each pipeline and main, records showing the procedures used and the data developed in establishing its maximum allowable operating pressure. The record shall contain at least the following information: i. Time and data of Test;

ii. Pipe Specifications of sections under test; iii. Elevation profile and the location of the test section and testing points, if applicable; iv. Testing medium used; v. Test pressure at lowest elevation;

vi. Test duration; vii. Pressure and temperature recording charts, if applicable; viii. Pressure-Volume applicable; chart, if

ix. Location of leaks or failures and description of repair action taken. h) Acceptance of Test The test is successful when the

pipeline has withstood the strength test, and during the test period there is no observable drop in pressure that cannot be accounted for by temperature changes. 16.12.3 Termination of Testing The pipeline shall be slowly depressurized at a moderate and constant rate. During dewatering, care shall be taken to properly dispose the discharging water in order to avoid pollution, damages to fields under cultivation and/or existing structures and interference with the traffic. 16.12.4 Pre-tested Pipe Pipe used for making repairs shall be pre-tested to a pressure equal to or greater than the original pipeline strength test pressure. 16.12.5 Preservation of Pipeline If the pipeline is to be preserved for a specified duration before it can be commissioned, the pipeline shall be completely filled with water with sufficient quantities of corrosion inhibitors, depending upon the quality of water and the period of preservation, or with a non-flammable, non-toxic gas and at a suitable pressure. 16.13 CONTROL AND LIMITING OF GAS PRESSURE Maximum Allowable Operating Pressure for Steel or Plastic Pipelines or Mains Consistent with Table 16.12.2.5 of this standard shall be adhered to. 16.14 VALVES Notwithstanding the foregoing provisions of this clause, sectionalizing block valves equipped with automatic closing devices should be provided for sour gas pipelines in order to minimize the volume of hydrogen sulphide that could be released in the event of a pipeline failure. 16.15 PIPE BOOK A pipe and welding book shall be

maintained for all projects. The purpose of the pipe book shall be to indicate and maintain as a permanent record the exact position in the pipeline of each pipe length and each pipeline material like valves, scraper traps, bends, and flanges and other fittings installed in the project. Each item shall be recorded by its identification number. Location of each weld including weld number, welder number, type of welding and electrode, weld treatment and the details of used equipment for radiography shall be recorded in the pipe book.

17.0

OPERATING AND MAINTENANCE PROCEDURES

All provisions of B 31.8 Chapter V and OISDSTD-138 shall apply.

18.0
18.1

CORROSION CONTROL
COATING REQUIREMENTS Coatings shall: a) Electrically isolate the external surface of the pipeline system from the environment; b) Have sufficient adhesion to effectively resist underfilm migration of moisture; c) Be ductile to resist cracking;

d) Have a strength or otherwise be protected to resist damage due to normal handling (including concrete coating application, or river weight installation, where applicable) and soil stress; e) Be compatible with cathodic protection system. 18.2 ELECTRICAL ISOLATION a) This clause shall not take precedence over recognized electrical safety practices and codes. b) Where insulating devices are installed to provide electrical isolation of pipeline systems to facilitate the application of corrosion control, they shall be properly rated for

temperature, pressure, and electrical properties, and shall be resistant to the commodities carried in the pipeline systems. These devices shall not be installed in enclosed areas where combustible atmospheres are likely to be present unless precautions are taken to prevent arcing. (Refer Clause 18.4 of this standard) c) Pipeline system shall be installed so that the belowgrade or submerged portions are not in electrical contact with any casing, foreign piping systems or other metallic structures. This shall not preclude the use of electrical bonds where necessary. d) Provision shall be made to prevent harmful galvanic action at below-grade or submerged connections between copper and steel piping. Consideration should be given to: i) Installing an insulated coupling or insulating gasket set between the copper and steel, or ii) Protecting the piping with an insulating coating material to provide a spatial separation of not less than 0.5m between bare copper and steel. 18.3 ELECTRICAL CONNECTIONS AND MONITORING POINTS

installation. 18.4 ELECTRICAL INTERFERENCE

18.4.1 Fault Current Interference Fault current interference shall be taken into consideration. NOTES: a) Fault current resulting from lighting or upset conditions of electrical facilities could result in serious damage to coating and pipe wall and danger to personnel. These adverse effects may occur where a pipeline is close to the grounding facilities of electrical transmission line structures, sub-stations, generating stations or other facilities that have high short circuit current-carrying grounding networks. b) Where a buried pipeline system is close to grounding facilities, remedial measures may be necessary to control the effect of these fault currents in order to reduce the resultant rise in potential gradient in the earth near the pipeline system to an acceptable level. c) Safety appliances shall be provided against lightning, stray current interference from foreign objects at HT pipeline crossings. 18.4.2 Induced Potential Interference

18.3.1 Where a higher current carrying capacity is required, a multistrand conductor shall be used and the strands shall be arranged into groups no larger than No.6 AWG. Each group shall be attached to pipe with a separate charge. Attaching test leads directly to the pipe by other methods of brazing is prohibited. 18.3.2 The following paragraph is added: When a thermit welding process is used for electrical lead installation on pressurized pipelines, precautions shall be taken to avoid possible failure of the pipeline during installation due to loss of material strength at the elevated welding temperatures. Where a thermit welding process is not deemed suitable. Consideration shall be given to other methods of

Pipelines paralleling alternating current electrical transmission lines are subject to induced potentials as well as the effects mentioned in Notes to Clause 18.4.1 above. a) When studies or tests show that alternating current potentials will be or are being induced on a buried pipeline system, devices shall be installed to reduce these potentials to a tolerable level. b) When such pipelines are under construction, or when personnel are in contact with the pipelines, special precautions shall be taken to nullify the possible effects of induced alternating current potentials. 18.4.3 Safety Requirements

shall be monitored periodically. Following precautions shall be taken: 18.7 a) Employ blowdown connections that will direct the gas away from the electric conductors; b) Install bonding across points where the pipeline is to be separated and maintain this connection while the pipeline is separated; c) Make a study in collaboration with the electric company on the common problems of personnel safety, corrosion, electrical interference and lighting problems. 18.5 EXISTING INSTALLATIONS INTERNAL CORROSION CONTROL

18.7.1 Any gas whose water dew point is at all times below the minimum pipeline operating temperature is considered to be non-corrosive, unless tests or experience indicate otherwise. 18.7.2 Any gas whose water dew point exceeds the minimum pipeline operating temperature is considered to be corrosive, unless tests or experience indicate otherwise. 18.7.3 Any gas containing hydrogen sulphide or carbon dioxide whose water dew point exceeds the minimum pipeline operating temperature is considered to be corrosive, unless tests or experience indicate otherwise. 18.7.4 Any gas containing hydrogen sulphide or carbon dioxide whose water dew point is maintained below the minimum pipeline operating temperature by dehydration, or is suitably inhibited, is considered to be non-corrosive, unless tests or experience indicate otherwise.

18.5.1 Existing Coated Pipeline Systems Cathodic Protection shall be applied and maintained on all existing coated pipeline systems. 18.5.2 Existing Bare Pipeline Systems Investigations shall be made to determine the extent or effect of corrosion on existing bare pipeline systems. Where these investigations indicate that continuing corrosion will create a hazard, corrosion control measures or other remedial action shall be undertaken. 18.5.3 Cathodically Protected Pipeline Systems Temporarily out of Service Cathodic Protection systems shall be maintained on any pipeline system temporarily out of service. 18.6 TEMPORARY CATHODIC PROTECTION SYSTEM When considered necessary, a temporary Cathodic Protection system with sacrificial anodes shall be installed to ensure adequate protection of pipeline from external corrosion from the time the pipeline is laid in the trench till the permanent Cathodic Protection system is commissioned. The temporary cathodic protection system shall preferably be installed simultaneously keeping pace with the pipeline laying/installation work and

19.0

MISCELLANEOUS
All provisions of B 31.8 Chapter VII shall apply.

20.0

REFERENCES
DIN

30670

Polyethylene Sheathing of Steel Tubes and of Steel Shapes and Fittings. Corrosion Protection Tapes and Heat Shrinkable Sleeves- Coatings made from Corrosion Protection Tapes and Heat Shrinkable Sleeves for Underground Pipelines.

30672

AWWA C203-86 Standard for Coal-Tar Protective Coatings and Linings for Steel Water Pipelines-Enamel and Tap-Hot Applied. BSI BS 4146 Specifications for Coal-Tar Based Hot

1987

Applied Coating Materials for protecting iron and Steel, including suitable Primers where required.

organisation whose standards and specifications appear above. DIN: Deutsches Institute for Normung Obtainable from: Foreign Standards Distribution Beuth Verlag GmbH Burggrafen Strasse 4-10 D-1000 BERLIN 30 British Standards Institution 2, Park Street, London : WIA 2BS Telephone : 01-6299000 Telex : 266933

NACE TM-01-77 Testing of Metals for Resistance to Sulphide Stress Cracking at Ambient Temperatures. BSI TM-02-84 Testing of Metals for Resistance to Stepwise Cracking. MR-01-75 Sulphide Stress Corrosion Cracking (SSCC) Resistant Metallic Material for Oil Field Equipment Name and address of the

AWWA American Water Works Association 6666 West Quincy Avenue, Denver, Colorado 80235