Eng052 20erw 002 PL Bod 0001 000 - 02

ORIGINATOR: CLIENT: DOCUMENT NUMBER:
PETROFAC ZALLAF ENG052-20ERW-002-PL-BOD-

0001-000
PROJECT:
NC-200 ERAWIN FIELD EPF PHASE- I (PLAN B)
CONTRACT NO: PROJECT NO: HOLDS: PAGE NO:
ENG052-20ERW JI-2047 No 1 OF 42
TITLE
PIPELINE DESIGN BASIS
THIS DOCUMENT IS DEVELOPED FROM FEED PIPELINE DESIGN BASIS

DOC NO. 413060-16086-000-PL-BOD-0001-000
Dheeraj Digitally signed by Dheeraj Singh

DN: cn=Dheeraj Singh, o=Petrofac International
Limited, ou=Engineering Manager,
Singh
[email protected], c=AE
Date: 2022.02.11 15:47:15 Z
YOUSS Digitally
signed by
Moham Digitally signed
YF EFFRANG
YOUSSEF
02 Issued for Design MI edIbrahim DS/RH 08/02/2022

by Mohamed
FRANGIEH Ibrahim
Date: Date: 2022.02.11
10:18:33 Z
2022.02.11
IEH 15:58:02
+04'00'
01 Issued for Review YF MI DS/RH 07/11/2021
REVISION DESCRIPTION OF REVISIONS PREP’D CHK’D APPRV’D DATE
This document is issued pursuant to an Agreement between Petrofac Facilities Management Limited and Zallaf Libya Exploration and Production Oil & Gas
Company which agreement sets forth the entire rights, obligations and liabilities of those parties with respect to the content and use of the report. Reliance by
any other party on the contents of the document shall be at its own risk. Petrofac makes no warranty or representation, expressed or implied, to any other party
with respect to the accuracy, completeness or usefulness of the information contained in this report and assumes no liabilities with respect to any other party’s
use of or damages resulting from such use of any information, conclusions or recommendations disclosed in this document.
PROJECT: PROJECT NO: CLIENT: DOCUMENT NUMBER:
NC-200 ERAWIN FIELD EPF PHASE- I JI-2047 ZALLAF ENG052-20ERW-002-PL-
(PLAN B) BOD-0001-000
DOCUMENT TITLE: ORIGINATOR: REV: DATE: PAGE NO:
PIPELINE DESIGN BASIS PETROFAC 02 08/02/2022 2 of 42
SHEETS INDEX AND REVISIONS

Rev. Section Revision Description
01 All Review for Review
02 All Review for Design
Note: Revision Table to be used on Post-AFD Issues
HOLDS
Hold No. Section Description
ABBREVIATIONS
Abbreviation Description
(PLAN B) BOD-0001-000
CONTENTS
1.0 ABBREVIATIONS .................................................................................................................... 5

2.0 INTRODUCTION ...................................................................................................................... 6
2.1 Project Background ................................................................................................. 6
2.2 General Definitions................................................................................................... 8
3.0 SCOPE AND PURPOSE .......................................................................................................... 9
3.1 Battery Limits ........................................................................................................... 9
4.0 DESIGN CODES, STANDARDS AND REFERENCES .......................................................... 10
4.1 Design Specifications and References ................................................................. 10
4.1.1 Company Standards and Specifications .............................................................. 10
4.1.2 International Codes and Standards ...................................................................... 10
4.1.3 Technical Papers .................................................................................................... 12
4.1.4 Reference Documents............................................................................................ 12
5.0 PIPELINE DESIGN DATA ...................................................................................................... 14
6.0 PIPELINE ROUTE STUDY & ANALYSIS .............................................................................. 15
6.1 Pipeline Route for Export Pipeline ........................................................................ 15
6.2 Pipeline Route for Production Flowlines .............................................................. 15
6.3 C). Co-ordinate System .......................................................................................... 16
6.4 Pipeline Installation Philosophy ............................................................................ 17
6.5 Pigging Philosophy ................................................................................................ 17
6.6 Corrosion Protection.............................................................................................. 17
6.7 Pipeline Road, Livestock and Wadi Crossings .................................................... 18
7.0 DESIGN CALCULATIONS ..................................................................................................... 19
7.1 Location Class & Design Factors .......................................................................... 19
7.2 Pipe Wall Thickness Calculations ......................................................................... 19
7.3 Pipeline Road Crossing Calculations ................................................................... 20
7.4 Hydrostatic Test Pressure Calculations ............................................................... 20
7.5 Upheaval Buckling Calculation ............................................................................. 21
7.6 Stress Analysis....................................................................................................... 21
7.7 Block Valve Design ................................................................................................ 21
7.8 Pipeline Stability..................................................................................................... 23
8.0 MATERIAL SELECTION ........................................................................................................ 24
8.1 Line Pipe ................................................................................................................. 24
(PLAN B) BOD-0001-000
8.2 Pipe Bends .............................................................................................................. 24

8.3 Fittingsand Flanges ............................................................................................... 25
8.4 Valves ...................................................................................................................... 25
8.5 Pig Launcher and Receiver.................................................................................... 26
8.6 Pig Signallers.......................................................................................................... 27
8.7 Corrosion Monitoring Fittings ............................................................................... 27
8.8 Isolation Joints ....................................................................................................... 27
8.9 Field Girth Weld Joint Coating .............................................................................. 28
8.10 Welding ................................................................................................................... 28
8.11 Spare Materials ....................................................................................................... 29
8.12 Cathodic Protection ............................................................................................... 29
8.13 Fibre Optical Cable (FOC) Installation .................................................................. 29
9 SUPPORTS............................................................................................................................ 30
10 PROXIMITY TO OTHER FACILITIES .................................................................................... 31
11 CONSTRUCTION................................................................................................................... 32
11.1 General .................................................................................................................... 32
11.2 Pipeline Crossings ................................................................................................. 32
11.3 Pipeline Burial Depth ............................................................................................. 32
11.4 Pipeline Separation Distances............................................................................... 32
11.5 Pipeline Location Marking and Warning ............................................................... 32
12 PRE-COMMISSIONING AND COMMISSIONING .................................................................. 34
12.1 Caliper Pigging ....................................................................................................... 34
13 ENVIRONMENTAL CONDITIONS ......................................................................................... 35
14 HSE PLAN ............................................................................................................................. 36
14.1 General .................................................................................................................... 36
14.2 Installation Contractor HSE Plan........................................................................... 36
14.3 Specifications ......................................................................................................... 36
15 DESIGN DATA SUMMARY.................................................................................................... 37
15.1 Design Data Summary – 12 inch Oil export Pipeline NC-200 EPF to N115 ......... 37
15.2 Design Data Summary –6 inch Production Flowlines from E Fields to EWT ..... 39
15.3 Design Data Summary –8 inch Pipeline from EWT to EPF .................................. 41
(PLAN B) BOD-0001-000
1.0 ABBREVIATIONS
A/G Above Ground

B/G Below Ground
ASME American Society of Mechanical Engineers
ASTM American Society for Testing and Materials
API American Petroleum Institute
CC Corrosion Coupon
CP Cathodic Protection
CS Carbon Steel
EPCC Engineering, Procurement, Construction & Commissioning
Gr. Grade
GES General Engineering Specification
HSS Heat Shrink Sleeves
FBE Fusion Bonded Epoxy
FEED Front End Engineering Design
FOC Fiber Optic Cable
HSE Health, Safety and Environment
ID Internal Diameter
ICCP Impressed Current Cathodic Protection
ISO International Organization for Standardization
3LPP 3-Layer Polypropylene
3LPE 3-Layer Polyethylene
MIJ Monolithic Isolation Joint
MSR Material Selection Report
MTO Materials Take Off
NPS Nominal Pipe Size
OD Outside Diameter
P/L Pipeline
ROW Right of Way
SC Sampling Connection
WI Water Injection
WDW Water Disposal Well
WIW Water Injection Well
WSW Water Source Well
ZLOG Zallaf Libya for Exploration and Production of Oil and Gas
(PLAN B) BOD-0001-000
2.0 INTRODUCTION
2.1 Project Background
Erawin Project consists of the development of NC-200 E, G and H oil accumulations. NC-200 E, G
and H fields lay in Murzuq basin southwest of Akakus Oil Operations El Sharara production
facilities. E field is around 100 km from NC-115 GOSP-B. These fields were discovered and
appraised by REMSA between 2003 and 2009 by drilling and testing 3 exploration and 4 appraisal
wells. NC-200 block was assigned to Zallaf Libya in September 2017 and the Field Development
Plans (FDP) for the 3 existing discoveries were approved by NOC in April 2018.
Figure 1: NC-200 Geographical Location
For the Surface Facilities, Zallaf adopted development strategy in a 2-phase approach during the
FEED preparation. An Early Production Facility (EPF) consisting of one train of 10,000 BOPD oil
and 9,000 BWPD produced water separation capacity and located by well E-01 was selected for
Phase 1. These rates exclude the 10% design margin. In addition, Phase 1 would entail the
construction of a 12-inch exportation pipeline of about 100 km to Akakus NC-115 GOSP-B and a
20,000 bbl/d capacity Produced Water Treatment and Injection/Disposal Plant.
During the Post-FEED studies, Zallaf deleted Produced water treatment, injection / disposal scope
for Phase-1 along with implementation of various value engineering points.
(PLAN B) BOD-0001-000
Permanent Facilities Phase 2 would involve the design and construction of one separation train of
10,000 BOPD oil and 9,000 BWPD produced water capacity and addition or expansion of water
handling facilities and other auxiliary infrastructure as necessary.
Expected hydrocarbon production plateau rates are 16,000 BOPD oil and associated gas. The
maximum forecasted produced water rate during NC-200 production life is 20,000 BWPD.
Export tie back pipeline to NC-115 GOSP-B should be suitable for batch and continuous operation.
At NC-115 GOSP-B receiving end and crude oil will be discharged to existing storage tank.
In April 2021, Company stated their intent to go for a rental early works processing facility EWT
(procured by Company) to fast-track oil production and this strategy had been named as Plan B.
EWT will be designed for 10,000 BOPD, associated gas and 3,000 BWPD as water cut.
Plan B broadly comprises of following systems:
i. Wellheads: 4 nos. of wells (E1, E4, E5 & E7) are considered as part of Plan B.
ii. Flowlines: 4 nos. of flowlines from wells E1, E4, E5 & E7 will be routed till EPF area along with
FO Cable
iii. EPF: EPF / Processing facilities shall be by COMPANY. Crude oil Export scraper launcher will
be provided by Contractor.
a. Pipeline from 4 nos. of flowlines from EPF area to EWT and Export oil pipeline routing
from EWT to oil export pipeline near Crude oil export scraper launcher will be carried out
by Contractor along with suitable Telecommunication radio system at Temporary Camp.
b. The temporary Inlet manifold along with a rental processing facility including all utilities,
Power and control system shall be procured, installed, commissioned, operated, and
maintained by Company.
iv. 12” Export Pipeline along with telecommunication system
v. Brownfield and Greenfield work in existing NC-115B facility with fiscal metering skid, Metering
control room, Containerized substation, DG set, Diesel tank with necessary
Telecommunication system.
(PLAN B) BOD-0001-000
2.2 General Definitions
Description Description Definition
Front End Engineering Design (FEED) and any relevant design

FEED information handed over by COMPANY to CONTRACTOR for purposes
of the DESIGN
All those design and services activities conducted by CONTRACTOR

DESIGN
forming part of the WORK as described in the TECHINICAL ANNEX
COMPANY/ ZALLAF
or Zallaf Zallaf Libya Exploration and Production of Oil and Gas Company
CONTRACTOR Petrofac Facilities Management Limited
Zallaf Libya Exploration and Production of Oil and Gas Company

ZLOG
(COMPANY/ ZALLAF or Zallaf)
Organisation performing the Procurement Activity.

PURCHASER
Where PURCHASER is CONTRACTOR
VENDOR/
The party that manufactures or supplies equipment and services to the
SUPPLIER/ SUB-
PURCHASER.
CONTRACTOR
SHALL The word “shall” is used to indicate that a provision is mandatory.
The word “should” is used to indicate that a provision is not mandatory,

SHOULD
but recommended as good practice.
SITE NC-200 ERAWIN FIELD

(PLAN B) BOD-0001-000
3.0 SCOPE AND PURPOSE

This document establishes the basis of design and summarises the design information for the
following Off-plot and Oil Export Pipeline.
12 inch, Oil Export Pipeline from NC-200 to NC115 GOSP-B.
6 inch, 4 no’s of flowlines from “E” field (E1, E4, E5 and E7) to future EPF 13-slots manifold
6 inch, 4 no’s of flowlines (E1, E4, E5 & E7) from future EPF 13-slots manifold to EWT 4-slots
manifold
8 inch, 1 no of pipeline from EWT to Oil export pipeline pig launcher area at EPF
3.1 Battery Limits

The battery limit between the Off-Plot (ASME B31.4 / B31.8 scope) and the On-Plot (ASME B1.3
scope) works are indicated in the Piping & Instrumentation Diagrams (P & IDs) referenced in
section 3.0.
(PLAN B) BOD-0001-000
4.0 DESIGN CODES, STANDARDS AND REFERENCES

The following codes/standards/references identified under this clause shall be applicable for the
Design, Engineering, Construction/ Installation, Inspection, Testing and Commissioning of the
entire pipeline systems as part of this project scope. If no revision number or issued date is
indicated, reference shall be made to the revision available as of 09-July-2019.
Priority of the documents shall be as follows:
- Local statutory (Libyan) requirements
- The Contract
- International standards.
- NOC specification-If required
In the event of any inconsistency, conflict or discrepancy between any of the Standards,
Specifications and Regulatory requirements, the inconsistency shall be brought to the attention of
the COMPANY for resolution.
Any proposed deviations to the referenced specifications, codes and standards, and Design Data
shall be identified in writing with clarifications and shall be subject to prior approval from the
COMPANY.
4.1 Design Specifications and References
4.1.1 Company Standards and Specifications
GES R.01 General engineering specification Pipelines material

specification
GES R.02 General Engineering Specification – Pipeline Systems
4.1.2 International Codes and Standards
API 5L Specification for Line Pipe
Steel Pipelines Crossings for Railroads and

API RP 1102
Highways
API 6D Specification for Pipeline and Piping Valves
Steel Gate Valves - Flanged and Butt-welding Ends,

API 600
Bolted Bonnets
API 598 Valve Inspection and Testing
API 1104 Standard for Welding Pipelines and Related Facilities
ASME B31.3 Process Piping

(PLAN B) BOD-0001-000
Pipeline Transportation Systems for Liquids and

ASME B 31.4
Slurries
ASME B 31.8 Gas Transmission and Distribution Piping Systems
ASME B 36.10M Welded and Seamless Wrought Steel Pipe
ASME B 16.5 Pipe Flanges and Flanged Fittings
ASME B 16.9 Factory Made Wrought Butt Welding Fittings
ASME B 16.20 Metallic Gaskets for Pipe Flanges
ASME B 16.21 Non-Metallic Gaskets for Pipe Flanges
ASME B 16.11 Forged Fittings, Socket Welding and Threaded
ASME B 16.25 Butt welding Ends
ASME B 16.34 Valves- Flanged, Threaded and Welding End
ASME B 16.48 Line Blanks
Factory Made Wrought Steel Butt Welding Induction

ASME B 16.49
Bends
ASME B 1.20.1 Pipe Threads, General Purpose
Standard Specification for Carbon and Low-Alloy

ASTM A350 Steel Forgings, Requiring Notch Toughness Testing
for Piping Components
Standard Specification for Carbon and Alloy Steel
ASTM A694 Forgings for Pipe Flanges, Fittings, Valves, and Parts
for High-Pressure Transmission Service
Standard Specification for Wrought High-Strength

ASTM A860
Ferritic Steel Butt-Welding Fittings
Standard Marking System for Valves, Fittings,

MSS SP- 25
Flanges and Unions
MSS SP- 44 Steel Pipeline Flanges
Specification for High-Test Wrought Butt-Welding

MSS SP- 75
Fittings
MSS SP-97 Integrally Reinforced Forged Branch Outlet Fittings

(PLAN B) BOD-0001-000
Quality Standard for Steel Castings and Forgings for

Valves, Flanges, Fittings and Other Piping
MSS SP-53
Components – Magnetic Particle Examination
Method
Boiler and Pressure Vessel Code- Non-Destructive

ASME Section V
Examination
Boiler and Pressure Vessel Code- Welding and

ASME Section IX
Brazing Qualifications
Boiler and Pressure Vessel code Rules for

ASME Section VIII
Construction of Pressure Vessel
External coatings for buried or submerged pipelines

BS EN ISO 21809-1 used in pipeline
transportation systems - 3LPE and 3LPP
External coatings for buried or submerged pipelines

BS EN ISO 21809-3 used in pipeline
transportation systems – Field Joint Coatings
EN 10204 Metallic Products – Types of Inspection Documents
ISO 9001 Quality Management System Requirements
4.1.3 Technical Papers
▪ American lifelines Allianz: Guidelines for the design of buried steel pipe
▪ OTC 6335 - Design of Submarine Pipelines Against Upheaval Buckling
4.1.4 Reference Documents
The following documents shall be referred when required:
Document No Description
ENG052-20ERW-000-PR-BOD-0001-000 Process Design Basis and Design Criteria
ENG052-20ERW-000-ST-BOD-0001-000 Civil & Structural Design Basis
ENG052-20ERW-000-PE-BOD-0001-000 Piping Design Basis

(PLAN B) BOD-0001-000
Document No Description
ENG052-20ERW-000-EL-BOD-0001-000 Electrical Design Basis
ENG052-20ERW-000-IC-BOD-0001-000 Control and Automation Design Basis
ENG052-20ERW-006-TE-BOD-0001-000 Telecom Design Basis
ENG052-20ERW-000-ME-BOD-0001-000 Mechanical Design Basis
ENG052-20ERW-002-PL-BOD-0002-000 Pipeline Stress Analysis Design Basis
ENG052-20ERW-002-PL-PMS-0001-000 Pipeline Material Specification
ENG052-20ERW-002-PL-SPC-0001-000 Specification for Barred Tees
ENG052-20ERW-002-PL-SPC-0002-000 Specification for Pipeline Isolating Joints
ENG052-20ERW-002-PL-SPC-0004-000 Specification for Induction Bends
ENG052-20ERW-002-PL-SPC-0003-000 Specification for Pipeline Ball Valves
ENG052-20ERW-002-PL-SPC-0005-000 Specification for Pipeline Flanges
ENG052-20ERW-002-PL-SPC-0008-000 Specification for Pipeline Construction
ENG052-20ERW-002-PL-SPC-0009-000 Specification for Pipeline Concrete Weight Coating
ENG052-20ERW-000-ML-SPC-0001-000 Cathodic Protection Specification
ENG052-20ERW-000-ML-REP-0001-000 Material Selection Report
ENG052-20ERW-000-ML-SPC-0004-000 Specification for Pipeline Field Joint Coating
ENG052-20ERW-000-ML-SPC-0002-000 Specification for Painting and Coating

ENG052-20ERW-000-PE-PMS-0001-000 Piping Material Specification
ENG052-20ERW-002-PR-PID-0002 SHT.001 P&ID Oil Producer Well Flowline
ENG052-20ERW-002-PR-PID-0002 SHT.002 P&ID Wellhead List of Lines and Instrument Tag

Numbers
ENG052-20ERW-002-PR-PID-0003-000 EPF Inlet Headers
ENG052-20ERW-002-PR-PID-0004-000 Export Pipeline Scraper Launcher

ENG052-20ERW-002-PR-PID-0005-000 Crude Oil Export Pipeline – BVS
ENG052-20ERW-002-PR-PID-0006-000 Export Pipeline Scraper Receiver
ENG052-20ERW-002-PL-MAP-0001-000 Pipeline Route Map - Overall

(PLAN B) BOD-0001-000
5.0 PIPELINE DESIGN DATA

For pipeline system design data, refer to Section 15.0.
(PLAN B) BOD-0001-000
6.0 PIPELINE ROUTE STUDY & ANALYSIS

As part of the Pre-FEED works, COMPANY has performed the route selection of the new Oil Export
Pipeline followed by Topographical and Geotechnical Survey. This shall be further validated,
optimised and confirmed by Contractor during the Detail Design phase.
Similarly, COMPANY has performed the desktop route study using Google imaginary for all the
new Production Flowlines, this shall be further validated, optimised and confirmed by
Topographical survey by Contractor during the Detail Design phase.
For details of pipeline route, refer to project Pipeline Route Map Drawings referenced in section
3.0.
6.1 Pipeline Route for Export Pipeline
As part of the Pre-FEED works, COMPANY has performed the route selection for the new Oil
export pipeline followed by Topographical and Geotechnical Survey. The new 12-inch buried CS
Oil Export Pipeline from EPF at NC-200 to the existing NC-115 facility is proposed to run within the
new/existing concession block areas with an independent/dedicated pipeline corridor.
As part for works, CONTRACTOR shall review the proposed routes and confirm/update the route
alignments to ensure constructability, operability, maintainability and HSSE aspects. Accordingly,
CONTRACTOR shall review/re-visit and prepare/update the alignment sheet drawings for the new
Oil export pipeline.
Topographical and Geotechnical survey performed during FEED phase of the project which made
available to CONTRACTOR for the new Oil Export pipeline shall be used as rely upon information
for detail engineering.
At both stations ends, the Pipeline centreline alignment is modified and there is no Topographic
survey information available at FEED stage as indicated in the Alignment sheet drawings for these
re-routed pipeline sections. Hence, CONTRACTOR shall perform Topographic route survey for
these relevant sections and complete the Alignment Sheet drawings as part of Detail Design scope.
In sand dune areas, the profile of ground R.O.W. shall generally follow the natural terrain with some
minor alteration to enable proper construction of pipeline and ensure safe bending and laying of
pipeline.
FEED Geotechnical survey will be used for pipeline route cathodic protection design and trenchless
crossing of the highway if any.
6.2 Pipeline Route for Production Flowlines
The new 6 inch Flowlines from Production Wells at ‘E’ field to near EPF manifold are proposed to
run within the new concession block areas with an independent/dedicated pipeline corridor as
shown in the Pipeline Route map drawings, Dwg.No. ENG052-20ERW-002-PL-MAP-0001-000.
The new 6-inch Flowlines from near EPF future 13-slot manifold to EWT unit 4-slot manifold and
new 8 inch pipeline from EWT to oil export pipeline pig launcher area are proposed to run within
the new concession block areas with an independent/dedicated pipeline corridor. However, the
route of pipelines shall not interfere \ clash with future Plan A design built and construction activities.
(PLAN B) BOD-0001-000
Topographical and Geotechnical survey NOT performed during FEED phase of the project
therefore, as part for works, CONTRACTOR shall perform a detailed Flowline route selection
survey to finalize the flowline routes. The survey shall include as a minimum:
• Topographic survey.
• Geotechnical investigation
• Determination of the number, type, depth (where applicable), length and location of all
crossings.
• The CONTRACTOR or CONTRACTOR’s Survey SUB-CONTRACTOR shall prepare a
detailed report for the finding/ assessments along the proposed route centreline and shall
submit to COMPANY for review, comment and acceptance.
COMPANY to refer to Flowlines route survey report, Doc.No. ENG052-20ERW-002-PL-REP-0025-
000 for the survey details of flowline route & associated facilities.
The approved route map for flowlines shall be the basis for the topographical survey. Detail
topographical survey will be conducted for the flowlines route and associated facilities during detail
engineering by qualified Third-Party SUB-CONTRACTOR, approved by COMPANY.
The approval of the Pipeline route from various authorities shall be part of the CONTRACTOR’s
scope of work.
Based on the topographical survey drawings provided by Survey SUB-CONTRACTOR, Pipeline
alignment sheets will be prepared and issued to COMPANY for review and approval.
For the details of flowlines route, refer to project Pipeline route map drawings, Dwg.No. ENG052-
20ERW-002-PL-MAP-0002-000
6.3 C). Co-ordinate System
All coordinates or grid positions for the pipeline network shall be as shown in below Table. The
datum shall be used for defining the coordinates of the pipeline network and any features within it.
The coordinate reference system for the on-Plot (EPF area, EWT, NC-115 GOSP-B area, BVS &
Tie-in locations) is same that used for the pipeline sections. The coordinate system within on-plot
area and its conversion details to Pipeline system shall be recorded on drawings and documents
as required.
Data Parameters
Projection TM-CM 12 E
Ellipsoid Int.Hy 1924
Horizontal Datum ELD-79-SSL
References SAT 07-03 / SAT 07-04

(PLAN B) BOD-0001-000
Data Parameters
Units Linear = Meter, Angular = Degree
Topographical Sub-Contractor shall establish a horizontal and vertical control system based on this
coordinate system.
6.4 Pipeline Installation Philosophy

All Production flowlines and Oil Export Pipeline shall be predominantly buried except the ends they
shall be installed on the supports above grade. The depth of cover for the Oil Export Pipelines,
shall be as per ASME B31.4 and for Production Flowlines it shall be as per ASME B31.8.
The depth of cover, width of trench and other construction details shall be as per alignment sheets
and typical details shown in the pipeline construction drawings.
Special considerations shall be given to pipelines installed in weak soils (e.g., peat or soft sand,
false fills), at dyke and sand dune crossings, etc. where differential settlements may lead to pipeline
loss of integrity.
6.5 Pigging Philosophy

All the new oil export Pipeline and Flowlines (from ‘E’ fields to EPF) in this project scope are
basically designed piggable. The new Oil Export Pipeline shall be designed piggable with
permanent pig trap facilities and the new Production Flowlines will be designed piggable with a
provision for connecting the temporary Pig Trap / Mobile unit through a flanged pipe section and
Barred Tee connection to facilitate the commissioning, decommissioning and cleaning pigging
activities. Hence, no Operations / Maintenance pigging is envisaged for this Flowlines.
For the temporary Pig traps area, there is no requirement of concrete hard stand and catch pit.
However, the plot area should be graded.
All mainline valves shall be full bore ball valves to facilitate the pigging operation.
All branches on the mainline, where the branch size is larger than 25% of the pipeline diameter of
above 6”, and 35% of the pipeline diameter of 6” it shall be provided with a barred tee as it is
designed as piggable. The strap-on or clamp type Non-Intrusive pig signallers shall be installed to
detect the pigs during pigging operations.
6.6 Corrosion Protection

In accordance with project MSR, Doc.No.ENG052-20ERW-000-ML-REP-0001 ) the corrosion
allowance is considered as 1.5 mm for Oil Export pipeline, 3.0 mm for Production Flowlines. As per
GES R.01 clause 3.6, a minimum corrosion allowance for the Pipelines shall be 1.5mm.
As per MSR and COMPANY recommendation, the buried Oil Export Pipeline, Production Flowlines
shall be externally coated with 3LPE and provided with ICCP.
(PLAN B) BOD-0001-000
The A/G section of pipelines and flowlines shall be externally painted as per recommendation from
Project Painting specification document, Doc.No. ENG052-20ERW-000-ML-SPC0002-000.
6.7 Pipeline Road, Livestock and Wadi Crossings

The design of road crossings for the new Pipelines and Flowlines shall comply with the
requirements of API RP 1102. Pipeline crossing angle shall be 90 degrees as practicable and in
no case, it shall be less than 30 degrees.
Road crossing profile shall be made with bends (cold – field fabricated or elastic) to accommodate
the change in depth of cover. Graded road crossing shall be installed by open cut method in
accordance with typical details of the pipeline construction drawings & COMPANY approved
Pipeline Construction Specification.
As per GES R.02, the minimum clear cover to the pipe at road crossings shall be 1200mm
minimum. This shall be verified through detailed road crossing calculations in accordance with API
RP 1102. The extent of higher thickness wall pipe shall be typically extended to minimum 5 meter
on either side of the roads.
The design and construction of road crossings shall meet all the requirements of COMPANY
approved Pipeline Construction Specification and API RP 1102.
Combined livestock and light vehicle crossing shall be installed at 5 km intervals in accordance
with typical pipeline construction drawings & alignment sheets. Livestock crossings are not
recommended for Flowlines less than 2 Km and for Flowlines greater than 2Km long, livestock
crossings are recommended. The livestock crossing may be combined with graded road and track
crossings. The minimum cover depth for Livestock crossing shall be 1200mm.
For all roads and wadi Type B & C crossings, line pipes with a wall thickness of design factor 0.6
shall be used. For Livestock and wadi Type A crossing, line pipes with a wall thickness of design
factor of 0.72 shall be used. The minimum cover depth for Type-A Wadi crossing and flood plain
crossing shall 1500mm and 2000m for type B &C Wadi crossings.
For details of typical road, livestock and wadi crossing design, refer to Project Typical Construction
drawings.
(PLAN B) BOD-0001-000
7.0 DESIGN CALCULATIONS

The new Oil Export Pipeline and Production Flowlines installed as part of this project shall be
designed to withstand all installations, testing and operating conditions/loads. All necessary
calculations shall be carried out to verify the structural integrity and stability of the pipeline for the
combined effect of pressure, temperature, bending (elastic), soil/pipe interaction, external loads
and other environmental parameters.
The new Pipelines and, Production Flowlines and associated facilities (described under section 3.0
above) shall be designed and engineered in accordance with the standards/codes listed in section
4.0 of this document.
7.1 Location Class & Design Factors

Location class is not applicable for new Oil Export Pipelines as per design code ASME B31.4. So,
as recommended in the GES R.02 specification the “Location Class” as provided in the Table
854.1-1 of ASME B31.8 and design factors in Table 841.1.6-1 of ASME B31.8 shall be followed.
However, the Production flowlines are design as per ASME B31.8 and is categorized as Location
Class 1 Div. II.
7.2 Pipe Wall Thickness Calculations

In accordance with GES R.01 clause 3.5.3, selected wall thickness shall not less than minimum
thickness mentioned below.
Line Size Minimum Nominal Wall thickness
Sch 80
1” to 2” (i.e., for 1” – 4.55mm / 0.179 inch)
for 2” – 5.54mm /0.218 inch)
Sch 40
(i.e., for 3” – 5.49mm / 0.216 inch,
3” to 6”
‘for 4” – 6.02mm / 0.237 inch),
‘for 6” – 7.11mm / 0.280 inch)
Sch 20
(i.e., for 8” – 6.35 mm / 0.25 inch)
8” to 12”
‘for 10” – 6.35 mm / 0.25 inch)
‘for 12” – 6.35 mm / 0.25 inch)
As part of this project strategy, Client will free-issue the Line Pipes (CS, API 5L Gr. X42, PSL-2) for
Production flowlines and Oil Export Pipeline to the CONTRACTOR. The minimum ordered line pipe
thickness for Production Flowlines and Oil Export pipeline is 0.375” (9.525mm). For Oil Export
Pipeline, the wall thickness calculation shall be performed in accordance with ASME B31.4 and for
Production Flowlines, the wall thickness calculation shall be performed in accordance with ASME
(PLAN B) BOD-0001-000
B31.8. This is to verify the suitability of ordered thickness for bend thinning (elastic bend, cold bend
and Induction bend), Von Miss condition (equivalent stress) and Vacuum conditions.
7.3 Pipeline Road Crossing Calculations

The detailed road crossing calculations shall be performed for pipelines as per API RP 1102 to check
/ verify the selected wall thickness.
The input data considered for the traffic loads includes standard traffic profile with special vehicle
considered as per RIGNote-1 (this is the worst load that can occur). The road crossing calculations
shall be performed for this worst-case loading.
The buried cover of minimum 1200 mm shall be maintained from top of pipeline to the top of road
surface shall be as per GES R.02. In no case at road crossings, the cover shall be less than 1200
mm. Casing pipe/ Sleeve shall not be considered for road crossings as there are chances of
annular corrosion. All the road crossings by open cut method. Trenchless crossings such as HDD,
thrust boring method, etc. shall not be considered.
The modulus of soil reaction (i.e., E’) is considered as “Soft to medium clays and silts with low to
medium plasticities, loose sands and gravels”. This would become the worst-case scenario for
crossing calculations.
Note-1: As per COMPANY instruction, the total load of RIG wheels shall be approximately 700 Ton
with 4 axle and 8 wheels. Hence for road crossing calculations, 100 Ton per front wheel load with
Single axle will be considered.
The buried pipe tends to ovalize under the effects of earth and live loads and this ovality shall be
limited to 2.5% as per clause 4.2 of American lifelines Allianz technical paper on “Guidelines for the
design of buried steel pipe”.
Detailed report with calculation and results will be presented in project document, ENG052-20ERW-
002-PL-CAL-0001-000 : Pipeline Wall thickness calculation.
7.4 Hydrostatic Test Pressure Calculations

The test pressure test medium and test duration for all the new Pipelines and Flowlines in this project
scope shall be as per the guidelines of ASME B31.4 and ASME B31.8 as applicable.
As part of FEED, preliminary hydrostatic test pressure calculations are performed for Oil Export
Pipeline as it is a cross country pipeline with significant elevation variations along its route and the
impact of static head would require to be verified to determine the number of test sections in the high
level hydrotest diagram. For other Pipelines and Flowlines, the length and elevation are not critical
and hence only the hydrostatic test pressure calculations are performed.
As part of Detail Design, the hydrostatic test pressure and number of test sections shall be calculated
by CONTRACTOR for all the new Pipelines and Flowlines in this Project in accordance with ASME
B31.4 /B31.8 as applicable.
002-PL-CAL-0002-000: Pipeline Mechanical calculation.
(PLAN B) BOD-0001-000
7.5 Upheaval Buckling Calculation

The buckling calculations shall be performed accordingly to the OTC 6335 Technical paper.
7.6 Stress Analysis

The detailed flexibility analysis shall be performed for Pipelines and Flowlines system considering
design parameters established in this document during detail design phase of this project.
As part of this project scope, the stress analysis shall be carried out for Oil Export Pipeline, Oil
Pipeline and all oil Production flowlines to determine allowable pipe movement and supports (anchor,
axial stop and guide) requirements.
The equivalent stress for all the new Pipelines and Flowlines shall be performed for the maximum
design temperature as per code ASME B31.4/ B31.8 unless otherwise specified. The necessary
stress checks/ calculations (e.g., equivalent stresses and combined stress, etc.) shall be performed
for the above ground pipelines sections to ensure that induced stresses are within the allowable
stress value limits as per design codes.
Use of anchor blocks will be avoided and sufficient flexibility will be provided to the station pipe works
to absorb thermal expansion. Also, seismic condition is not considered as the lines are buried. This
shall be evaluated based on stress analysis outcomes.
The Installation/tie-in temperature shall be considered as 210 C.
Refer, Doc. No. Doc.No. ENG052-20ERW-002-PL-BOD-0002-000 Pipeline Stress analysis design
basis for Design criteria and basis to be used for Pipeline Flexibility/Stress Analysis for the project.
Soil data shall be established from the FEED Geotechnical Investigation Report for oil Export
Pipeline Corridor and EPC Geotechnical Investigation Report for flowlines.
The consolidated values shall be listed in Pipeline stress analysis design basis for soil parameters
obtained from various Trial pits/Bore holes along the Pipeline Corridor for depth range
corresponding to typical pipeline installation i.e., of 0.5m-2.0m. The same shall be utilized for
Design criteria and basis the Pipeline Flexibility & Stress Analysis for the project.
Pipeline Stress Analysis shall be carried out by computer software program CAESAR-II latest
edition.
7.7 Block Valve Design

As part of FEED, there are two (2) new BVS’s are proposed for the Oil Export Pipeline and their
locations are indicated in relevant Project drawings. The locations are selected based on the
Topographic survey alignment sheet profile and is not site verified. Hence, these BVS locations shall
be reviewed, re-visited and modified (if necessary) as part of detail design by CONTRACTOR.
It shall be noted that Pipeline BVS’s shall be preferably located on a local high spot with good access,
and never in a Wadi or low point.
(PLAN B) BOD-0001-000
The BVSs shall be designed, engineered and constructed mainly as per ASME B31.4 and other
COMPANY specifications. BVS arrangement shall be installed inside concrete pit for safety reasons.
The elevation of pipeline at BVS section shall be maintained and shall be aligned to match the
adjacent pipeline sections.
The details of work at each BVS station shall include the following as a minimum, but not limited to
the following:
• Design, Supply and installation of the mainline valve and By-pass arrangement
• Main line valve assembly shall be manual gear operation.
• Design, supply and installation of all By-pass valve assemblies, mechanical fittings, flanges,
valves and piping etc.
• Design, supply and installation of all valves as per P&ID.
• Mechanical fittings, flanges and piping.
• Design, supply and installation of all Instruments including pressure gauges, pig signaller,
etc.
• By-pass arrangement.
• Grading and compaction and all-around fence with suitable access graded road, main and
escape gates.
• Sign boards as per COMPANY specifications.
• Access barriers, crossovers, access platforms.
• Power supply as applicable.
• Design and Grading, excavation & backfilling, compaction/re-compaction, cleaning of soil
excess, etc.
• Design, supply, installation and Construction of concrete pits (see Civil design basis for more
details).
• Design, supply and installation Sign boards as per COMPANY specifications
• Design, supply and installation of Access barriers, crossovers, access platforms as per
operational practice, requirements and recommendations of the COMPANY
• Design, supply and installation of all Civil foundations as per Civil design basis in reference
at section 4.1.4.
Feasible sleeper/supports shall be provided to ensure that no stress is transferred to the BVS piping
while manual depressurization of the pipeline. CONTRACTOR shall submit the design calculation
with stress analysis report for COMPANY review and approval.
(PLAN B) BOD-0001-000
7.8 Pipeline Stability

Pipelines are subjected to buoyant forces when they encounter high water table (such as Wadis) at
burial depth of the pipeline. In areas where positive buoyancy is identified, the buoyant forces are
counteracted by providing anti-buoyancy measures i.e., by providing external concrete coating of
required thickness over the corrosion coating.
Special considerations shall be given to pipelines installed in weak soils, culvert entries, etc., where
differential settlement may lead to high stress levels and possible loss of pipeline integrity by
providing pipeline anchors and expansion loops.
(PLAN B) BOD-0001-000
8.0 MATERIAL SELECTION

For detail material selection, refer to Project Material Selection Report (MSR) (Doc: ENG052-
20ERW-000-ML-REP-0001-000).
The basic material of construction for the pipeline shall be carbon steel for all new Pipelines,
Production Flowlines and Oil Export Pipeline.
8.1 Line Pipe

As part of Project execution strategy, COMPANY will free issue the Line pipes for Oil Export Pipeline
and Production Flowlines to the Construction contractor. The material of grade proposed by
COMPANY is Carbon Steel (CS) API 5L Gr. X42, PSL-2.
These Line pipes shall be coated externally as per recommendations in Material Selection report.
Similarly, there is no internal coating envisaged as per Material Selection report. COMPANY free
issued Line pipes for buried pipeline has been externally coated by means of a three (3) layer
Polypropylene coating (3LPE) system in line with ISO 21809-1 and Project Specification for Pipeline
3-LPP and 3-LPE external coating, Doc no. 413060-16086-000-ML-SPC-0002-000.
Minimum total 3LPE coating thickness is 3mm for oil export pipeline and flowlines. Refer section 6.3
of 413060-16086-000-ML-SPC-0002-000 for further details on coating thickness.
The Pipes for ASME B31.3 on-plot piping such as ancillary piping for pipeline pig trap systems shall
be procured in accordance with piping Material Specification (PMS), Doc.No. ENG052-20ERW-000-
PE-PMS-0001-000.
8.2 Pipe Bends

The minimum elastic bending radius shall be as per the elastic bend calculation, however the
minimum elastic bending curvature radius shall not be less than 1000D, where D is the Pipe outside
diameter. However, Pipeline Mechanical calculations, Doc.No. ENG052-20ERW-002-PL-CAL-0002-
000 shall be referred for selected minimum elastic bend radius for each pipeline size. Elastic bending
shall be utilized for gradual changes in elevation achieved by profiling the trench and laying the
pipeline to fit the contour without cold bending. Cold field bends or hot formed bends will be used at
locations of vertical or horizontal changes of direction where elastic bends cannot be used. All hot
and cold bends shall be tested with a gauging plate of 95% of the nominal inside diameter of the
heaviest wall component of connecting line pipe.
The induction bends supplied for this project shall comply with all the requirements of specification
for Induction Bends, Doc no. ENG052-20ERW-002-PL-SPC-0004-000.
Cold bends (site fabricated by CONTRACTOR) shall be used on the Pipelines/ Flowlines wherever
required. As per clause 404.2.2 of ASME B31.4 and Table 841.2.3-1 of ASME B31.8, the minimum
bend radius shall be 30D for a pipe size of 12 inch and smaller and the use of induction bend shall
be avoided as much as possible. Induction bends are envisaged when there is space constraint and
larger radii cold bends cannot be accommodated. In any case, the wall thickness of bends after
thinning shall not be less than the corresponding calculated pipe thickness.
(PLAN B) BOD-0001-000
The use of Hot-Induction shall be avoided, , Induction bends can be used at the station plot entry/
exit locations and block valve stations to absorb thermal expansion when required. Minimum bending
radii for hot bends should be 5D. Induction Bends shall be procured as per Project Specification
prepared as part of this project. The wall thickness of induction bend after thinning shall not be less
than the corresponding calculated pipe thickness (required design thickness).
The use of mitre bends shall not be allowed.
8.3 Fittings and Flanges

All branches on the mainline, where the branch size is larger than 25% of the pipeline diameter of
above 6”, it shall be provided with a barred-tee as it is designed as piggable.
The barred tees shall be designed in accordance with MSS SP-75 and relevant material
Specification. All mainline tees shall be provided with the bars in order to avoid a pig getting stuck
during pigging operation. The barred tee material shall be equivalent to the main pipeline material,
grade, thickness and strength. The barred tees supplied for this project shall comply with all the
requirements of specification for Barred Tee Doc no. ENG052-20ERW-002-PL-SPC-0001-000.
The pipeline fittings and flanges shall be made of high strength low alloy CS materials and
compatible with the Line pipe material in terms of weldability. The bevel geometry (end preparation)
constraints shall conform to ASME B31.4 for Oil export Pipeline and as per ASME B31.8 for
Production flowlines. Fittings and flanges shall be procured as per Project specification document,
Doc no. ENG052-20ERW-002-PL-SPC-0005-000. Flanges shall be in accordance with the MSS SP-
44/ ASME B16.5 and applicable Specification for Pipeline Flanges. Flanges shall be weld neck,
raised face (RF) for upto & including ASME Class 600#. The bore of welding neck flanges in piggable
pipelines shall match to the inside diameter of the connecting pipe or fitting. Flanges material grade
shall be equivalent to connecting pipeline material grade.
All fittings for instruments and branch connections shall be of minimum size DN50 (2 inch) and for
mechanical strength reasons; there should be no branch or instrument connection smaller than DN
50 (2 inch).
Weldolets/ Branch outlet fittings larger than size DN 100 (4 inch) shall not be used and use of
sockolet on pipeline is restricted.
8.4 Valves
All mainline valves (within ASME B31.4/ B31.8 code break-limit) shall be in accordance with API 6D
and as per approved project material specification documents. All mainline valves shall be ball valves
with full bore to facilitate the pigging operation.
The material for body shall be CS and trim shall be SS 316/316L.
All above ground Pipeline valves including BVS underground valves in pit shall have flanged ends;
tight shut-off (TSO), soft seats with double isolation and bleed (DIB-2 i.e., single valve with two
seating surfaces) arrangement.
Valves shall be operated by hand wheel. The actuation type for valves shall be as per relevant
valve data sheet.
(PLAN B) BOD-0001-000
Pipeline Valves shall be in accordance with the API 6D and applicable project specification for
Pipeline Ball Valves, Doc.No. ENG052-20ERW-002-PL-SPC-0003-000.
All Pipeline isolation ball valves of 4 inch and higher size shall be provided with sealant injection/
greasing, cavity and drain points for seat and stem along with necessary fittings and valves.
The pipeline valves of size 6” and larger shall be provided with cavity vent and drain piping with
isolation flanged ball valve with blind flange. The vent and drain connection piping shall be fully
welded into the body, threaded fittings shall not be allowed. The drain piping shall be sloped toward
the isolation valve to prevent liquid accumulation within the drain piping.
8.5 Pig Launcher and Receiver

A permanent Pig Launcher and Receiver facilities shall be provided for new Oil Export Pipeline for
launching and receiving of pigs. Pig traps shall be procured in accordance with project Specification.
Pig Launcher and Receiver shall be equipped with the Quick Opening End Closure (QOEC). The
end closure shall be fitted with mechanical lock so that the end closure cannot be opened whilst the
vessel is under pressure.
The material of the pig trap barrels shall be equivalent to the main pipeline material, grade and
strength.
A corrosion of 1.5mm shall be considered for Minor and major barrel of the pig trap as per
recommendation of Material Selection Report.
For the Flowlines (E1, E4, E5 & E7) between wellheads & EPF only provision for temporary pigging
shall be considered. Supply of mobile pig traps for flowlines for future pigging and cleaning
operations by COMPANY.
Pig traps shall be designed to be suitable for the intelligent pigs to allow pigging operations for
baseline using an intelligent pig as well as cleaning pigs for the removal of any debris in the pipeline.
However, Baseline Intelligent pig survey is not part of CONTRACTOR scope of work.
CONTRACTOR shall perform the design calculations for pig trap equipment’s in accordance with
the requirements of pipeline codes and project specifications.
CONTRACTOR shall define allowable forces and moments for all nozzles. All nozzle elevations, pig
trap saddles and piping routing near to pig traps shall be modified to match the VENDOR data and
shall be finalized by CONTRACTOR.
CONTRACTOR shall design, supply and install Jib crane and Pig handling system suitable for the
Pig Launcher and Receiver for oil export pipeline system. Separate design calculation and report
along with drawings shall be submitted for COMPANY review and approval.
The Quick Opening End Closure (QOEC) material shall be compatible to the material of the pig trap
barrels.
(PLAN B) BOD-0001-000
8.6 Pig Signallers

Non-Intrusive type pig signallers (i.e., strap-on or clamp-on type) shall be used at pig trap stations
and at Block valve stations. Pig signallers shall be procured as per Project Specification. Intrusive
type pig signallers are not envisaged.
The pig signaller sensor clamp-on/strap-on belt shall be suitable for desert conditions without
sunshade with life span of not less than this project design life without replacement.
Pig Signallers shall be capable of indicating the passage of all types of pigging devices, including
intelligent pigs.
Non-intrusive interchangeable type pig signallers shall be installed as a minimum at the following
locations:
• Launcher and receiver pig trap barrels
• Downstream of the barred tee (Pig launcher)
• Upstream of barred tee (Pig receiver)
• Each Block Valve Stations (BVS) in and out
External strap-on belt material used shall be SS316L and suitable for buried application.
8.7 Corrosion Monitoring Fittings

Corrosion Coupon (CC) and Corrosion Probe (CP) assembly shall be provided in line with the
requirements of Project Material Selection Report (Doc# ENG052-20ERW-000-ML-REP-0001-000).
Flarweld type Corrosion Monitoring Access (CMA) Fittings shall be supplied in accordance with the
specification for Corrosion Monitoring Access (CMA), Doc.no. ENG052-20ERW-002-PL-SPC-0006-
000.
Corrosion Monitoring Access pits shall be provided at the approved points. The concrete pits shall
be provided with all the necessary facilities for easy access of the inspection personnel and the
cover shall be sealed tight to prevent ingress of sand and rainwater.
As part of FEED for Oil Export pipeline, Corrosion Monitoring pits (at lowest points) shall be installed
at 6 O’ clock position of the buried Pipeline and shall be equipped with a minimum of two (02) number
access fittings (CC and CP) at each pit location. Common Retrieving tools suitable for all pit locations
shall also be provided by the CONTRACTOR as identified in the Specification for CMA fittings.
For Flowlines, Corrosion Monitoring access fittings are provided at the above ground piping sections
at the station ends (on-plot) at 12 O’ clock position.
Location of CMA fittings shall be as marked in P&IDs and respective Pipeline alignment sheets.
8.8 Isolation Joints

For the new Oil export Pipelines and Flowlines, monolithic isolating joints shall be installed above
ground on both ends of line and shall be used to isolate the CP systems from pipeline on-plot above
ground sections. Isolating joints shall be designed and procured in accordance with Project
(PLAN B) BOD-0001-000
Specification. Insulating Gasket will be used for the Pipelines between EPF & EWT where required
to isolate the CP systems for Pipelines. All insulation gaskets shall be metallic reinforced type.
For Isolation Joints, the pup pieces shall be supplied by the CONTRACTOR for welding and testing
at vendor’s production facility in case Vendor finds difficulty in sourcing the pipes as per the
requirements of Project Line Pipe specification. The pup pieces shall be of the same grade, strength
and wall thickness as the line pipe material to which they will subsequently be welded.
Where, Vendor intent to purchase forging pup pieces instead of using pups from line pipe then, the
Isolating Joints and pup piece material, grade, strength, wall thickness and diameter shall be
equivalent as that of the main pipeline.
The overall length of the isolation joint & pup piece shall be optimized by vendor to avoid any
damages to the internals of isolation joint such as filler material, due to heat generated during field
welding to pipeline. Welding proximity to the non-metallic seals shall be avoided by providing
sufficient length. Final assembly of Isolating Joint including pup piece shall be tested with a gauging
plate of 95% of the nominal internal diameter of connecting line pipe
Isolating Joints shall be supplied in accordance with the specification for Monolithic Isolation Joint,
Doc.no. ENG052-20ERW-002-PL-SPC-0002-000.
8.9 Field Girth Weld Joint Coating

For new Oil Export Pipeline and Production Flowlines, PE Heat shrink sleeves with manual
application shall be used for field girth weld coating. Heat Shrink Sleeves shall be designed and
procured as part of the Specification by CONTRACTOR.
The field HSS coating shall be applied by COMPANY approved Specialist coating CONTRACTOR
at site and for HSS, the coating thickness shall be as per the requirements of Project HSS
Specification document, Doc.no. ENG052-20ERW-000-ML-SPC-0004-000.
8.10 Welding
The welding shall be carried out as per COMPANY Standards and applicable international standards
listed / nominated in ASME B31.4/B31.8. CONTRACTOR shall prepare a project specific Pipeline
Welding Procedure Specification (WPS) and Procedure Qualification Record (PQR) and approved
by COMPANY before start of any welding works.
CONTRACTOR shall ensure that all welders employed on welding of line pipe shall be qualified in
accordance with API STD 1104 as amended by CONTRACTOR’s specification approved by
COMPANY. Post weld heat treatment (PWHT) is not required for field girth weld joints.
Butt welds shall be radiographed for pipeline joints as per project welding and NDT procedures.
Radiographic examination may be substituted for ultrasonic examination only with the prior approval
of the CONTRACTOR as specification approved by COMPANY. Ultrasonic examination shall only
be used where Radiographic examination methods are not practical.
Refer QA/QC project specifications for further details on Pipeline welding and NDT procedures.
(PLAN B) BOD-0001-000
8.11 Spare Materials

Sufficient spare materials except line pipes should be ordered to cover for route deviations, field
welding qualifications and possible damage during construction and for setup of a material
contingency stock for pipeline emergencies during Operational Phases.
As the Line pipe for pipelines systems is free issued by COMPANY, the adequate material for
contingency, shall be supplied by COMPANY when required.
8.12 Cathodic Protection

In addition to the corrosion protection by means of external coating of all buried steel pipes, the
pipelines shall be equipped with a corrosion protection system by means of an impressed current -
cathodic protection system as per Cathodic Protection Specification Doc.no. ENG052-20ERW-002-
ML-SPC-0002-000.
Buried sections of pipelines and flowlines shall be protected using an impressed current cathodic
protection system. The cathodic protection system shall be designed to provide protection against
corrosion for the design life of the pipelines.
Temporary cathodic protection shall be provided during the construction prior to the installation of
the permanent impressed current cathodic protection system. Details of temporary CP system shall
be submitted to Company for approval.
8.13 Fibre Optical Cable (FOC) Installation

One Fibre optical cable shall be installed along with the oil export pipeline and flowlines in the
same trench. Refer to Pipeline Typical Drawings, Telecom Design Basis (Plan-B): ENG052-
20ERW-006-TE-BOD-0001-000, Telecom Specification - Fibre Optic Cable: ENG052-20ERW-006-
TE-SPC-0001-001 for further details
(PLAN B) BOD-0001-000
9 SUPPORTS
The sections of above ground pipeline and associated piping system within the plot fence shall be
designed with adequate supports.
The preferred measure to allow the thermal expansion of buried pipeline at ends is by the aid of
sliding supports at above ground section of pipeline system as practicable and the use of anchor
blocks on the buried Pipeline/ Flowlines are avoided as part of FEED works as per agreement with
COMPANY. However, during detail design based on design or COMPANY requirement, the use of
Anchor block may be reviewed and considered (if required) by CONTRACTOR.
Pipe supports shall be designed in accordance with project specification/ standard for Pipe supports.
Supports for Pig traps of oil export pipeline shall be designed to carry the weight of the pig trap
system filled with water (or other fluids if their density is greater than that of water) together with the
weight of intelligent pigs.
The sections of above ground pipeline including isolating joints, pig trap valves, tie-line valves, kicker
valves and associated piping system within the plot fence shall be designed with adequate supports.
Pipe Supports between the over bend and the Isolating joint shall be electrically isolated to
maintain electrical isolation for the design life of the pipeline system. Similarly, the pipe supports in
the sections of pipeline (before insulating gasket break) within ASME B31.4 design code limit at
BVS shall be electrically isolated.
Pipe supports shall not cause coating damage to the pipeline and shall be designed to prevent
water and dirt from being trapped between the pipe support and the pipe.
(PLAN B) BOD-0001-000
10 PROXIMITY TO OTHER FACILITIES

The separation requirements between the pipeline permanent pig traps and other adjacent facilities
should be at least 15 meters. Pig trap systems should generally be located adjacent to each other
at a minimum distance of 10 meters, for ease of pigging operations.
The separation between temporary pigging facilities of Production flowlines shall be maintained at
3.5m to 5 m.
(PLAN B) BOD-0001-000
11 CONSTRUCTION
The project Pipelines and Flowlines shall be constructed as per Project routing alignment sheet
drawings and preliminary typical construction drawings prepared as part of the FEED. Further these
drawings shall be reviewed and updated as part of detail design to meet the COMPANY
requirements and site conditions to ensure the safe and successful installation of the Pipelines and
Flowlines.
Construction of pipeline shall also be in accordance with COMPANY approved Pipeline Construction
Specification and Pipeline construction drawings or as per EPC CONTRACTOR Construction
Specifications approved by COMPANY, Doc.No. ENG052-20ERW-002-PL-SPC-0008-000.
11.1 General
The project export Pipeline and Flowlines shall be constructed by Approved-For-Construction (AFC)
drawings, specifications and all applicable codes and standards.
The construction of carbon steel pipelines shall be in accordance with COMPANY Specifications
and Standards as amended by CONTRACTOR’s specification for Pipeline Construction, Doc.No.
ENG052-20ERW-002-PL-SPC-0008-000 approved by COMPANY.
11.2 Pipeline Crossings

Various crossing types, e.g., road (major/minor), existing pipelines/cables, powerlines, OHL, water
courses, wadi crossings, etc. are envisaged along the pipeline route.
The requirements for all crossings including crossing method and design shall be in accordance with
project design documents, facility owner’s requirements and specification for Pipeline Construction,
Doc.No. ENG052-20ERW-002-PL-SPC-0008-000.
All crossings shall meet the project Typical Drawings for respective crossings.
11.3 Pipeline Burial Depth

The pipeline shall be laid in a trench with the minimum required cover above the top of the pipeline
at crossings and Normal ground are outlined in section 15 for the respective flowlines and oil export
pipeline.
11.4 Pipeline Separation Distances

The minimum safety clearances between the new piping and existing facilities, inhabitant locations,
parallelism with OHL’s, third party facilities, existing cables, pipelines etc. shall be as per COMPANY
Specifications and Standards as amended by CONTRACTOR’s specification for Pipeline
Construction, Doc.No. ENG052-20ERW-002-PL-SPC-0008-000 approved by COMPANY.
11.5 Pipeline Location Marking and Warning

CONTRACTOR shall provide access barriers where required as per COMPANY Specifications and
Standards as amended by CONTRACTOR’s specification for Pipeline Construction, Doc.No.
ENG052-20ERW-002-PL-SPC-0008-000 approved by COMPANY.
(PLAN B) BOD-0001-000
Barriers shall be provided at all manholes along the pipeline route.

Access barriers shall be designed, fabricated and installed as per aforementioned documents.
At all tarmac road crossings including highways/expressways, railways, populated/industrial city
area if any, the Access barrier shall be provided as per project typical drawings.
All markers (such as Kilometer (Aerial) markers, Pipeline (chainage) markers, FOC markers,
crossing markers, CP markers, pipeline boundary Pole markers. etc.) and signboards shall be
installed all along the route of the pipeline at locations marked in pipeline alignment sheets in
accordance with project typical drawings.
(PLAN B) BOD-0001-000
12 PRE-COMMISSIONING AND COMMISSIONING

Pre-Commissioning activities include cleaning, gauging, hydro testing (i.e., filling, pressurising,
depressurising, emptying) and drying of pipeline.
Commissioning commences when the complete system has been successfully hydro-tested,
dewatered, dried and nitrogen slug purged, after the hook-up of pipelines with Tie-in Valve and is
ready for operational duty.
Pre-commissioning and Commissioning procedures shall be prepared by CONTRACTOR and
approved by COMPANY.
During Pre-commissioning stage, if the commissioning is at a later date, the complete pipeline shall
be thoroughly dewatered, cleaned and dried/ purged and preserved to prevent unacceptable internal
corrosion during commissioning and operation of the pipeline.
The preservation procedure shall be developed by the Construction Contractor in accordance with
specification for Pipeline Construction, Doc.No. ENG052-20ERW-002-PL-SPC-0008-000 and it
shall be reviewed and approved by the COMPANY.
12.1 Caliper Pigging

After completion of pipeline installation work, the caliper pigging survey shall be carried out for 12’’
crude oil export pipeline. The caliper pigging survey shall be done by specialized sub-
CONTRACTOR approved by the COMPANY before placement of sub-contract order. A detailed
report shall be submitted to COMPANY for records after conducting the Caliper Pigging.
Following the successful Caliper pigging, CONTRACTOR shall submit all the records for COMPANY
review and approval. The caliper pigging survey is not applicable for flowlines and other pipelines.
(PLAN B) BOD-0001-000
13 ENVIRONMENTAL CONDITIONS
For environmental conditions, refer to Process Design Basis (Doc. No.: ENG052-20ERW-000-PR-
BOD-0001-000)
(PLAN B) BOD-0001-000
14 HSE PLAN
14.1 General
The HSE plan shall be customization of the COMPANY HSE Management System meeting
COMPANY’s proactive and reactive targets and reduced risks to ALARP (As Low As Reasonably
Practicable). Special attention given to: Safety and health risk assessment; and Hazard
identification, assessment and control.
14.2 Installation Contractor HSE Plan

The installation CONTRACTOR will produce a contract specific HSE Plan to be used for the duration
of the project. The plan will detail the CONTRACTOR HSE policy, organization, responsibilities,
journey management, emergency response, inspection/audit plans and other related HSE aspects
to be complied with throughout the contract. The document will be periodically reviewed and updated
as required.
The Installation CONTRACTOR personnel will have to attend the appropriate training as detailed in
the contract prior to the start of work. A full time Safety Advisor from the Installation CONTRACTOR
will be assigned to advise the project and Construction Manager on all HSE matters. Hazard
identification, assessment and control exercise will be carried out during the pre-mob HSE
Workshop, to identify the measures to be taken to minimize HSE risk/exposure for each activity. This
will be included in the HSE Plan and used for toolbox talks and work planning prior to the start of
each of work activity.
14.3 Specifications
For engineering, procurement and construction, the HSE requirements given in International
Standards & COMPANY procedures shall be followed.
(PLAN B) BOD-0001-000
15 DESIGN DATA SUMMARY
15.1 Design Data Summary – 12 inch Oil export Pipeline NC-200 EPF to N115
I. PIPELINE – General Description/ Data
Fluid Service Gross Fluid

Sour Service Non Sour [Sweet service as H2S is nil]
NACE sour, HIC test required Not Applicable
Pipeline design code / specification ASME B31.4
Approx. total length of Pipeline 96300 m
Proposed new P/L section starts at Pig Launcher facility plot located inside EPF at NC-200
Proposed new P/L section ends at Pig Receiver facility located at NC-115 GOSB.
Design Life 30 Years
Line pipe Manufacturing Method SMLS
Corrosion allowance (CA) 1.5 mm (0.059 inch)
II. PIPELINE – Mechanical
Pipeline location class Class 1 Div. 2
0.6 for On-plot and road / wadi crossings (For Wadi Type B & C)
Design Factors (DF) 0.72 for Off-Plot (including Wadi Type A/ flood plains and Livestock
crossings)
III. PIPELINE – Process

Design pressure (Max./Min.) 70 bar (g) (1015 psig) / FV
Min./ Max. operating pressure 47.5 / 63 Bar(g) (689 / 913.7 psig)
Field Hydrostatic Test Pressure As per ASME B31.4
ASME/ ANSI Flange rating CL 600#
Min./ Max. Design temperature (B/G) 0o C / 65o C (32 / 149º F)
Min./ Max. Design temperature (A/G) -2o C / 80o C (28.4 / 176º F)
Min./ Max. Operating temperature 32o C / 47o C (89.6 / 116.6º F)

Design Installation Temperature 21ºC
IV. PIPELINE – Calculated Values
Nominal Pipeline Size 12 inch (DN 323.9)
Pipeline Material Specification CS, API 5L Gr. X42, PSL-2
Pipeline OD (mm) 323.9mm (12.75 Inch)
Pipeline ID (mm) 304.8mm (12 Inch)
(PLAN B) BOD-0001-000
Line Pipe Wall Thickness 9.525mm (0.375 Inch) [For both DF=0.6 & 0.72]
V. PIPELINE – Coatings/CP
Cathodic Protection system Impressed Current Method
Pipeline Internal Coating Nil
Pipeline External Coating 3LPE

Type of field girth weld joint coating PE Heat Shrink Sleeves
VI. PIPELINE – Appurtenances
Pigging philosophy Pig Traps for Maintenance including Intelligent pigging
2
Number block valve stations (no’s) [ BVS #1 located at approx. KP CH: 31+654.5 and BVS #2 located
at approx. KP CH: 66+154.5]
VII. PIPELINE – Installation
Construction mode Buried
Min Cover depth in Normal ground 900 mm (as per Table 434.6-1 of ASME B31.4)
All Road crossings including
Min. Rig Road and Livestock 1.2m as per GES R.02
Cover crossings
depth Wadi Type A and Flood
1.5m
at Plain
Wadi Type B & C 2m
Field stress Relieving Not Required
(PLAN B) BOD-0001-000
15.2 Design Data Summary –6 inch Production Flowlines from E Fields to EWT

Approx. total length of Pipeline (m) 8160
Proposed new P/L section starts at Wells at E Field
Proposed new P/L section ends at Inlet manifold future EPF 13-slots manifold
Corrosion allowance (CA) 3 mm (0.118 inch)
0.6 for On-plot and road / wadi crossings (For Wadi Type B
& C)
Design Factors (DF)
0.72 for Off-Plot (including Wadi Type A/ flood plains and
Livestock crossings)
Design pressure (Max/Min) 47.5 bar (g) (689 psig) / FV
Min.- Max. operating pressure 2.7 - 4.7 bar (g) (39.2– 68.2 psig)
Min./ Max. Design temperature (B/G) - 10 / 65º C (- 14 / 149º F)
Min./ Max. Design temperature (A/G) - 10 / 80º C (- 14 / 176º F)
Min./ Max. Operating temperature 31.1 - 54.4° C (88 - 130º F)


Pipeline OD 168.3
Pipeline ID 149.25 mm (5.876 Inch)
Line Pipe Wall Thickness 9.525 mm (0.375 Inch) [For both DF=0.6 & 0.72]
(PLAN B) BOD-0001-000

No Operational / Maintenance Pigging envisaged and
hence no permanent pigging facility are installed. However,
Pigging philosophy the pipelines are designed Piggable and provided with lay
down area for Pre-commissioning /commissioning
operations (off-line).
Number block valve stations Nil
Min. Cover depth in Normal ground 610 mm (as per Table 841.1.11-1 of ASME B31.8)
All Road crossings

including Rig Road and 1.2m as per GES R.02
Min. Cover Livestock crossings
depth at Wadi Type A and Flood
1.5m
Plain
Wadi Type B & C 2m
(PLAN B) BOD-0001-000
15.3 Design Data Summary –8 inch Pipeline from EWT to EPF

Approx. total length of Pipeline (m) 460
Proposed new P/L section starts at EWT
Proposed new P/L section ends at Export Pipeline pig launcher area
Corrosion allowance (CA) 1.5 mm (0.059 inch)
0.6 for On-plot and road / wadi crossings (For Wadi Type B & C)
Design Factors (DF) 0.72 for Off-Plot (including Wadi Type A/ flood plains and
Livestock crossings)

Design pressure (Max./Min.) 70 bar (g) (1015 psig) / FV
Min.- Max. operating pressure 47.5 / 63 Bar(g) (689 / 913.7 psig)
Min./ Max. Design temperature (B/G) 0 / 65º C (32 / 149º F)
Min./ Max. Design temperature (A/G) - 2 / 80º C (28.4 / 176º F)
Min./ Max. Operating temperature 32°C / 47°C (89.6/ 116.6 ºF)

Pipeline OD 219.1
Pipeline ID 200.05 mm (7.876 Inch)

Line Pipe Wall Thickness 9.525 mm (0.375 Inch) [For both DF=0.6 & 0.72]
(PLAN B) BOD-0001-000

No Operational / Maintenance Pigging envisaged and hence no
Pigging philosophy permanent pigging facility are installed. However, the pipelines
are designed Piggable and provided with lay down area for Pre-
commissioning /commissioning operations (off-line).
Number block valve stations Nil
Min. Cover depth in Normal ground 900 mm (as per Table 434.6-1 of ASME B31.4)
All Road crossings
including Rig Road and 1.2m as per GES R.02
Min. Cover Livestock crossings
depth at Wadi Type A and Flood
1.5m
Plain
Wadi Type B & C 2m

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ORIGINATOR: CLIENT: DOCUMENT NUMBER:

PETROFAC ZALLAF ENG052-20ERW-002-PL-BOD-

PIPELINE DESIGN BASIS

THIS DOCUMENT IS DEVELOPED FROM FEED PIPELINE DESIGN BASIS

Dheeraj Digitally signed by Dheeraj Singh

02 Issued for Design MI edIbrahim DS/RH 08/02/2022

01 Issued for Review YF MI DS/RH 07/11/2021

REVISION DESCRIPTION OF REVISIONS PREP’D CHK’D APPRV’D DATE

SHEETS INDEX AND REVISIONS

01 All Review for Review

02 All Review for Design

Note: Revision Table to be used on Post-AFD Issues

1.0 ABBREVIATIONS .................................................................................................................... 5

8.2 Pipe Bends .............................................................................................................. 24

A/G Above Ground

Figure 1: NC-200 Geographical Location

iv. 12” Export Pipeline along with telecommunication system

2.2 General Definitions

Description Description Definition

Front End Engineering Design (FEED) and any relevant design

All those design and services activities conducted by CONTRACTOR

CONTRACTOR Petrofac Facilities Management Limited

Zallaf Libya Exploration and Production of Oil and Gas Company

Organisation performing the Procurement Activity.

SHALL The word “shall” is used to indicate that a provision is mandatory.

The word “should” is used to indicate that a provision is not mandatory,

SITE NC-200 ERAWIN FIELD

3.0 SCOPE AND PURPOSE

3.1 Battery Limits

4.0 DESIGN CODES, STANDARDS AND REFERENCES

4.1 Design Specifications and References

4.1.1 Company Standards and Specifications

GES R.01 General engineering specification Pipelines material

4.1.2 International Codes and Standards

API 5L Specification for Line Pipe

Steel Pipelines Crossings for Railroads and

API 6D Specification for Pipeline and Piping Valves

Steel Gate Valves - Flanged and Butt-welding Ends,

API 598 Valve Inspection and Testing

API 1104 Standard for Welding Pipelines and Related Facilities

ASME B31.3 Process Piping

Pipeline Transportation Systems for Liquids and

ASME B 31.8 Gas Transmission and Distribution Piping Systems

ASME B 36.10M Welded and Seamless Wrought Steel Pipe

ASME B 16.5 Pipe Flanges and Flanged Fittings

ASME B 16.9 Factory Made Wrought Butt Welding Fittings

ASME B 16.20 Metallic Gaskets for Pipe Flanges

ASME B 16.21 Non-Metallic Gaskets for Pipe Flanges

ASME B 16.11 Forged Fittings, Socket Welding and Threaded

ASME B 16.25 Butt welding Ends

ASME B 16.34 Valves- Flanged, Threaded and Welding End

ASME B 16.48 Line Blanks

Factory Made Wrought Steel Butt Welding Induction

ASME B 1.20.1 Pipe Threads, General Purpose

Standard Specification for Carbon and Low-Alloy

Standard Specification for Wrought High-Strength

Standard Marking System for Valves, Fittings,

MSS SP- 44 Steel Pipeline Flanges

Specification for High-Test Wrought Butt-Welding