Hazardous Liquid Pipelines

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Hazardous Liquid Pipelines

• ABC Company
• ABC Chemical Complex
• Engineering Specification

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Hazardous Liquid Pipelines

• 1.0 SCOPE
• Covers the design, materials, fabrication,
  construction, inspection, testing, operations,
  maintenance, and safety aspects of hazardous
  liquid pipeline systems
• Also covers the components including, but not
  limited to, pipe, relief devices, valves,
  fittings, flanges, bolting, gaskets, hangars, and
  supports.

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Hazardous Liquid Pipelines

• EXCLUSIONS
• Auxiliary piping such as water, air, steam,
  lubricating oil, gas, and fuel
• Pressure vessels, heat exchangers, pumps, meters,
  and other equipment not in scope
• Petroleum refinery, natural gasoline, gas
  processing, ammonia, carbon dioxide processing,
  and bulk plant piping covered in the scope of
  ASME/ANSI B31.3, Plant Piping.

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Hazardous Liquid Pipelines

• Exclusions (Continued)
• Gas transmission and distribution piping systems
  covered under ASME/ANSI B31.8
• Piping at or below 15 psi
• Piping above 15 psi if design temperature is
  below -20oF or above 250oF
• Design and fabrication of proprietary items of
  equipment, apparatus, or equipment

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Hazardous Liquid Pipelines

• INTENT
• Provide engineering specifications for safe
  construction, operation, maintenance, and
  inspection of ABC hazardous liquid pipelines
• Shall meet or exceed the requirements in
  ASME/ANSI B31.4 and DOT 49CFR195
• Not retroactive for existing pipelines which
  shall be inspected and tested to the Code used in
  original design and construction.

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Hazardous Liquid Pipelines

• 3.0 PIPING SYSTEMS DEFINITIONS
• General Terms (14)
• Piping Systems (20)
• Pressure Relief Stations and Regulators (3)
• Valves (2)
• Pipe and Piping Terms (2)
• Dimensional Terms (3)
• Mechanical Properties (5)
• Steel Pipe (3)

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Hazardous Liquid Pipelines

• 4.0 DESIGN, FABRICATION, OPERATION, AND TESTING
  TERMS
• Uprating (1)
• Pressure Terms (8)
• Temperature Terms (3)
• Stress Terms (5)

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Hazardous Liquid Pipelines

• 5.0 MATERIALS AND EQUIPMENT
• Acceptable Materials and Specifications
• Marking
• Material Specifications
• Steel Pipe
• Fittings
• Transportation of Line Pipe
• Conditions for Reuse of Line Pipe

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Hazardous Liquid Pipelines

• 6.0 WELDING
• Welding Terms
• Preparation for Welding
• Safe Practices in Cutting and Welding
• Welding Processes and Filler Metal
• Welding Qualifications
• Qualification Records
• Material Limitations
• Welder Requalification Requirements
• Qualification Records (WPS, PQR, Welder)

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Hazardous Liquid Pipelines

• 7.0 Design Conditions
• Provides a set of standards covering
• Specifications for, and selection of, equipment
  and piping components
• Acceptable methods of making branch connections
• Provisions for temperature changes
• Approved methods for support and anchorage of
  exposed and buried piping systems.

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Hazardous Liquid Pipelines

• Design Conditions (Continued)
• Exclusions
• Pipe Materials (Section 5)
• Welding Procedures (Section 6)
• Installation and Testing of Piping Systems
• Special Engineering Stresses Not Specifically
  Covered in Specification
• River crossings, inland coastal water areas,
  bridges, areas of heavy traffic, long
  self-supported spans, unstable ground, vibration,
  earthquake, thermal, etc.

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Hazardous Liquid Pipelines

• Allowable Stress Values
• S 0.72 x E x SMYS, psi (MPa)
• where 0.72 design factor
• E weld joint factor, normally 1
• Allowable stress values shall be determined for
• Used pipe or new/used pipe of unknown or ASTM 120
  specifications
• Pipe which is cold worked to meet SMYS and
  reheated to 600oF or higher shall be 75 of
  applicable stress value

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Hazardous Liquid Pipelines

• Allowable Stress Values (Continued)
• In shear shall not exceed 45 SMYS
• In bearing shall not exceed 90 SMYS
• Structural supports and restraints shall not
  exceed 66 SMYS
• Structural supports and restraints of unknown
  piping specifications shall be assigned an SMYS
  of 24,000 psi or less

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Hazardous Liquid Pipelines

• Limits of Calculated Stresses Due to Sustained
  Loads and Thermal Expansion
• Internal Pressure Stresses
• External Pressure Stresses
• Allowable Expansion Stresses
• Additive Longitudinal Stresses
• Additive Circumferential Stresses Due to
  Occasional Loads

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Hazardous Liquid Pipelines

• Limits of Calculated Stresses Due to Occasional
  Loads
• Operation
• Sum of longitudinal stresses produced by
  pressure, live and dead loads, and occasional
  loads, i.e. wind and earthquake shall not exceed
  80 SMYS
• Test
• Stress due to test conditions are not subject to
  above limitations

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Hazardous Liquid Pipelines

• Limitations on Design Pressure, P
• Shall not exceed 85 of mill test pressure
• Alternatively, shall not exceed 85 of field test
  pressure if mill tests are not available
• Limitations on SMYS
• Used pipe from Company stock with known
  specifications may be assigned full S value
• An S value 24,000 psi shall be assigned to pipe
  with unknown specifications

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Hazardous Liquid Pipelines

• Additional Requirements for Nominal Wall
  Thickness, t
• Shall not be reduced to less than 90 of the
  design thickness under any circumstances
• Allowances
• Corrosion (Not required if corrosion controlled)
• Threading and Grooving
• Weld Joint Factors
• Wall Thickness and Defect Tolerances

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Hazardous Liquid Pipelines

• Straight Pipe Under Internal Pressure
• Design wall thickness of steel pipe shall be
  calculated by the following equation
• t PiD/2S
• where Piinternal design gage pressure
• Doutside diameter of pipe, in.
• Sapplicable allowable stress value, psi

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Hazardous Liquid Pipelines

• Additional Pressure Design Considerations
• Flanges, Reducers, Fittings, Elbows, Bends, and
  Intersections
• Closures
• Quick Opening Closures
• Closure Fittings
• Closure Heads
• Fabricated Closures
• Bolted Blind Flange Connections

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Hazardous Liquid Pipelines

• Expansion and Flexibility
• Means of Providing Flexibility
• Amount of Expansion
• Properties
• Coefficient of Thermal Expansion
• (6.5x10-6in./in./oF)
• Modulus of Elasticity (29x106 psi)
• Poissons Ratio (0.3 for steel)

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Hazardous Liquid Pipelines

• Design of Pipe Supporting Elements
• Combined Stress Calculations
• Restrained Pipelines
• Unrestrained Pipelines
• Analysis
• Basic Assumptions and Requirements

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Hazardous Liquid Pipelines

• 8.0 CONSTRUCTION
• Construction Specifications
• Inspection Provisions
• Right-of-Way
• Handling, Hauling, Stringing, and Storing
• Damage to Fabricated Items and Pipe
• Ditching
• Welding
• Tie In

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Hazardous Liquid Pipelines

• CONSTRUCTION (Continued)
• Installation of Pipe in Ditch
• Backfilling
• Hot Taps
• Restoration of Right-of-Way and Cleanup
• Special Crossings
• Block and Isolating Valves
• Mainline Valves
• Scraper Traps

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Hazardous Liquid Pipelines

• CONSTRUCTION (Continued)
• Line Markers
• Corrosion Control
• Pump Station, Tank Farm, and Terminal
  Construction
• Storage and Working Tankage
• Electrical Installations
• Liquid Metering
• Liquid Strainers and Filters

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Hazardous Liquid Pipelines

• 9.0 INSPECTION
• General
• Shall assure compliance with material,
  construction, welding, assembly, and testing
  requirements of ABC Specifications, ASME/ANSI
  B31.4 and DOT 49CFR 195
• Qualification of Inspectors
• Inspection personnel shall be qualified by
  training and experience to the criteria in API 570

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Hazardous Liquid Pipelines

• Inspection Services
• Right-of-way and grading
• Ditching
• Line up and pipe surface inspection
• Welding
• Coating
• Cathodic protection
• Tie-in and lowering

• Backfilling cleanup
• Pressure testing
• Station construction
• River crossings
• Electrical installation
• Radiography
• Corrosion control
• external
• internal

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Hazardous Liquid Pipelines

• Inspection Services
• Backfilling cleanup
• Pressure testing
• Station construction
• River crossings
• Electrical installation
• Radiography
• Corrosion control
• external
• internal

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Hazardous Liquid Pipelines

• Type and Extent of Examination Required
• Visual
• Material-mechanical damage
• Permanent records Location of pipe, wall
  thickness, type, specification, and manufacturer
• Construction
• Surface defects before coating operation and
  during lowering-in and backfilling operations
• Pipe swabbing operation

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Hazardous Liquid Pipelines

• Proper alignment and condition of weld joint
  surface before welding
• Inspect stringer bead for cracks
• Remove irregularities on weld cap to prevent
  coating damage
• Inspect all repairs, changes, or replacements
  prior to backfilling operation
• Inspect fit of pipe to ditch prior to backfilling
• Inspect backfilling operations for quality and
  compaction of backfill, placement of material for
  erosion control, and possible coating damage

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Hazardous Liquid Pipelines

• Inspect cased crossings during installation to
  assure that the carrier pipe is supported,
  sealed, and insulated from the casing
• Inspect piping components other than pipe to
  insure damage-free condition and proper
  installation

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Hazardous Liquid Pipelines

• Supplementary Types of Examination
• Weld inspection and testing
• Complete in accordance with ABC Specs and
  ASME/ANSI B31.4
• Weld defect and repair
• Complete in accordance with ABC Specs and
  ASME/ANSI B31.4
• Coatings
• Use ABC Specs and ASME/ANSI B31.4

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Hazardous Liquid Pipelines

• 9.2 TESTING
• Testing of Fabricated Items
• Testing After New Construction
• Systems or Parts of Systems
• Testing Tie-Ins
• Testing Controls and Protective Equipment
• Hydrostatic Testing of Internal Pressure Piping
• Hydrotest to 1.25 times the internal design
  pressure for at least four (4) hours
• Use API 1110 for guidance in hydrostatic tests

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Hazardous Liquid Pipelines

• Treat hydrotest water with a bactericide and
  corrosion inhibitor
• Relieve excess pressure during the test as
  required
• Hydrotesting with gas or nonvolatile hydrocarbons
  is not permitted on ABC projects without written
  permission from Company management
• Leak Testing
• Reduce hydrotest pressure to design pressure and
  hold for an additional eight (8) hours

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Hazardous Liquid Pipelines

• Qualification Tests for Pipe
• Visual Examination
• Bending Properties
• Determination of Wall Thickness
• Determination of Weld Joint Factor
• Weldability
• Determination of Yield Strength
• Minimum Yield Strength Value
• Records

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Hazardous Liquid Pipelines

• 10.0 Operation and Maintenance Plans and
  Procedures
• Written detailed plans and training programs for
  employees
• Plan for external and internal corrosion control
• Written emergency plan
• Plan for reviewing changes in conditions
  affecting the integrity and safety of the piping
  system.

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Hazardous Liquid Pipelines

• Liaison with local authorities and other pipeline
  operators to prevent excavation accidents.
• Procedures to analyze all failures and accidents
  to determine the cause and prevent recurrence.
• Record system to administer the plans and
  procedures.
• Procedures for abandoning pipelines
• Procedures to assure public safety in pipeline
  operation and maintenance

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Hazardous Liquid Pipelines

• Operation and maintenance of piping systems in
  conformance with ABC Specifications, ASME/ANSI
  B31.4, and DOT 49CFR195.
• Plan and procedure modifications as required

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Hazardous Liquid Pipelines

• 10.2 PIPELINE OPERATIONS AND MAINTENANCE
• Operating Pressure
• The internal design pressure and pressure rating
  for all components shall not be exceeded in
  steady state operations.
• Pressure rise due to surges shall not exceed the
  internal design pressure at any point in the
  piping system by more than 10.

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Hazardous Liquid Pipelines

• Requalification of a piping system is required if
  a higher operating pressure produces a hoop
  stress more than 20 SMYS. Requirements in
  paragraph 456, ASME/ANSI B31.4 shall be followed
  without exception.
• Derating of a pipeline to a lower operating
  pressure in lieu of repair or replacement may be
  completed with the maximum operating pressure
  determined by paragraph 10.2.7, ABC
  Specification.
• Codes in effect during original construction
  shall be consulted for allowable stress and
  design criteria.

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Hazardous Liquid Pipelines

• Communications
• Markers
• Right-of-Way Maintenance
• Patrolling
• Pipeline Repairs
• Repairs shall be completed in accordance with ABC
  Specification, Repair of Pipelines.
• Allowable pipeline repairs and repair methods are
  summarized in B31.4 and ABC specifications.

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Hazardous Liquid Pipelines

• Railroads and Highways Crossing Existing
  Pipelines
• Use API 1102 to determine the total stress caused
  by internal pressure and external loads. If new
  external pipe loading exceeds 0.72SMYS, Company
  will install mechanical reinforcement, suitable
  protection, or increased pipe thickness.
• Installation of uncased carrier pipe is preferred.

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Hazardous Liquid Pipelines

• 10.3 PUMP STATION, TERMINAL, AND TANK FARM
  OPERATION AND MAINTENANCE
• Pressure limiting devices, regulators, flow
  controllers, relief valves, and other safety
  devices shall be inspected annually to determine
  condition and functionality.
• Inspect storage tanks in accordance with API 653.

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Hazardous Liquid Pipelines

• CORROSION CONTROL
• EMERGENCY PLAN
• RECORDS
• Necessary operational data
• Pipeline patrol records
• Corrosion records as required by B31.4
• Records for routine and/or unusual inspections
• Pipeline repair records

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Hazardous Liquid Pipelines

• 10.7 QUALIFYING A PIPING SYSTEM FOR A HIGHER
  OPERATING PRESSURE
• Review initial design and previous testing
• Determine present condition by leak surveys and
  other field inspections, examination of
  maintenance and corrosion control records, or
  other suitable means.
• Complete necessary repairs, replacements, or
  alterations.

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Hazardous Liquid Pipelines

• Maximum steady state operating pressure may be
  increased after compliance with the previous
  slide and one of the following provisions
• If the condition of the pipeline is consistent
  with the design and hydrotesting has been
  completed to a test pressure equal to or higher
  than required for the new steady state operating
  pressure, the system is approved for the higher
  operating pressure.
• The system is successfully hydrotested to a test
  pressure required for the higher operating
  pressure.

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Hazardous Liquid Pipelines

• 10.8 Abandoning a Piping System
• Disconnect all facilities to be abandoned from
  all transported sources, i.e., other pipelines,
  meter stations, control lines, and other
  equipment.
• Purge all facilities to be abandoned to replace
  the transported liquid and vapor with an inert
  material.
• Seal the ends of the piping system.

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Hazardous Liquid Pipelines

• 11.0 CORROSION CONTROL
• Scope
• External Corrosion Control
• Internal Corrosion Control
• Pipelines in High Temperature Service
• Stress Corrosion and Other Phenomena
• Records