14050642 100 PL DBM 0001_Pipeline Design Basis_Rev 1

EFFLUENT WATER TREATMENT AND INJECTION PLANT (NK) Project No. EF/1761 Page Rev Date

CONTRACT NO. 14050642 PIPELINE DESIGN BASIS Doc. No. : 14050642-100-PL-DBM-0001

Class 1

1 of 54 1 19.06.2016

Effluent Water Treatment And Injection Plant (NK)

PROJECT

:

CONTRACT NO

: 14050642

OWNER

: KUWAIT OIL COMPANY

CONTRACTOR

:

DOCUMENT NO.

: 14050642-100-PL-DBM-0001

DOCUMENT REVISION STATUS

: 1

DOCUMENT TYPE

: E (Engineering Drawing/Document)

Dodsal Engineering & Construction Pte. Ltd.

1

19.06.2016

Re-Issued For Design (Ref.14050642-KD-T-01011)

SV

AC

PC

0

17.06.2015

Issued For Design (Ref.14050642-KD-T-00882)

MD

AC

PC

B

02.06.2015

Re-Issued For Approval (Ref.14050642-KD-T-00172 & 14050642-KD-T-00038)

SV

AC

PC

A

17.11.2014

Issued For Review / Approval

PJ

SV

PC

Rev

Date

Description

Prepared By

Checked By

Approved By

EFFLUENT WATER TREATMENT AND INJECTION PLANT (NK) Project No. EF/1761 CONTRACT NO. 14050642 PIPELINE DESIGN BASIS Doc. No. : 14050642-100-PL-DBM-0001

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REVISION RECORD:

Revision No. A B 0

Reason for Revision

Date

Issued for Review / Approval Re-Issued for Approval Issued for Design

17.11.2014 02.06.2015 17.06.2015

1

Re-Issued for Design

19.06.2016



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TABLE OF CONTENTS 1.

GENERAL ..................................................................................................................... 7

2.

OBJECTIVE ................................................................................................................... 7

3.

PROJECT DESCRIPTION ............................................................................................. 7

4.

SCOPE OF THIS DOCUMENT ...................................................................................... 8

5.

TERMINOLOGY ............................................................................................................ 9

6.

5.1.

DEFINITIONS ..................................................................................................... 9

5.2.

ABBREVIATIONS ............................................................................................ 10

DESIGN CODES, SPECIFICATIONS AND STANDARDS .......................................... 11 6.1.

INTERNATIONAL CODES AND STANDARDS ............................................... 11

6.2.

PROJECT REFERENCE SPECIFICATION / ADDENDUMS / DRAWINGS / DOCUMENTS: ................................................................................................. 17

6.3. 7.

8.

9.

ORDER OF DOCUMENT PRECEDENCE ........................................................ 20

GENERAL DESIGN DATA .......................................................................................... 21 7.1.

BATTERY LIMIT .............................................................................................. 21

7.2.

UNITS OF MEASUREMENT ............................................................................ 21

7.3.

COORDINATE SYSTEM .................................................................................. 22

SITE CONDITION & DESIGN DATA ........................................................................... 23 8.1.

SITE CONDITION / ENVIRONMENT DATA ..................................................... 23

8.2.

BASIC DESIGN DATA ..................................................................................... 23

8.3.

PIPELINE CATEGORIES ................................................................................. 24

8.4.

DESIGN LIFE SPAN ........................................................................................ 25

8.5.

PIPELINE TEMPERATURE & PRESSURE ..................................................... 26

8.6.

PIPELINE FLANGE RATING PHILOSOPHY ................................................... 26

PIPELINE MATERIALS ............................................................................................... 27


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9.1.

GENERAL ........................................................................................................ 27

9.2.

LINE PIPE ........................................................................................................ 27

9.3.

CARBON STEEL PIPE DESIGN PROPERTIES .............................................. 28

9.4.

RTRP PIPE DESIGN PROPERTIES ................................................................ 29

9.5.

BRANCH CONNECTIONS ............................................................................... 29

9.6.

RTRP PIPE JOINTS ......................................................................................... 29

9.7.

MATERIAL CERTIFICATION ........................................................................... 30

PIPELINE FITTINGS ................................................................................................... 30 10.1.

PIPELINE BENDS ............................................................................................ 30

10.1.1 GENERAL ........................................................................................................ 30 10.1.2 ELASTIC BENDS ............................................................................................. 31 10.1.3 COLD FIELD BENDS....................................................................................... 32 10.1.4 HOT INDUCTION BENDS ................................................................................ 32

11.

12.

10.2.

BARRED TEE .................................................................................................. 32

10.3.

INSULATING FLANGE JOINTS / INSULATION GASKET KIT........................ 32

10.4.

PIG LAUNCHER/RECEIVER ........................................................................... 32

10.5.

PIG SIGNALLERS ........................................................................................... 34

10.6.

PIPELINE ANCHORS ...................................................................................... 34

10.7.

FLANGES, BRANCH CONNECTIONS AND FITTINGS .................................. 34

10.8.

VALVES ........................................................................................................... 35

PIPELINE ANCILLARIES ............................................................................................ 36 11.1.

PIPELINE TRACING ........................................................................................ 36

11.2.

PIPELINE MARKERS ...................................................................................... 36

11.3.

PIPELINE WARNING SIGNS ........................................................................... 36

PIPELINE DESIGN CRITERIA .................................................................................... 37 12.1.

GENERAL ........................................................................................................ 37

12.2.

PIPELINE WALL THICKNESS CALCULATION .............................................. 37

12.3.

DESIGN FACTOR ............................................................................................ 38

12.4.

STRESS CALCULATION AT ROAD CROSSINGS ......................................... 38

12.5.

PIPELINE AT ABOVE GROUND / BELOW GROUND TRANSITION .............. 38


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13.

14.

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12.6.

PIPELINE UPHEAVAL BUCKLING CHECK.................................................... 39

12.7.

ON-BOTTOM STABILITY OF PIPELINES IN WET AREAS ............................ 39

PIPELINE ROUTING ................................................................................................... 40 13.1.

GENERAL APPROACH ................................................................................... 41

13.2.

ROUTE ALIGNMENT SHEET .......................................................................... 41

13.3.

TERRAIN AND INSTALLATION ...................................................................... 42

13.4.

SEPARATION DISTANCES AND EXCLUSION ZONES ................................. 43

13.5.

TOPOGRAPHICAL & GEOTECHNICAL DATA ............................................... 49

DESIGN PHILOSOPHY AND PHYSICAL DATA ......................................................... 49 14.1.

PIGGING, HYDRO TESTING & INSPECTION ................................................. 49

14.2.

NON DESTRUCTIVE TESTING ....................................................................... 50

14.3.

PIPELINE DEWATERING AND DRYING ......................................................... 50

14.4.

FIRE AND SAFETY REGULATIONS ............................................................... 50

14.5.

SITE TIE-IN REQUIREMENTS ......................................................................... 50

14.6.

STRUCTURAL INTEGRITY: ............................................................................ 51

15.

WELDING REQUIREMENTS....................................................................................... 51

16.

TESTING AND PRE-COMISSIONING ......................................................................... 52

17.

CORROSION PROTECTION ....................................................................................... 52 17.1.

CATHODIC PROTECTION .............................................................................. 52

17.2.

EXTERNAL CORROSION ............................................................................... 53

ATTACHMENT-1: PIPELINE SCHEMATIC DIAGRAM ............................................................. 54


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GENERAL Kuwait Oil Company (K.S.C), hereafter referred as COMPANY, as a major player of global oil and gas sector has a long term strategy for the development of North Kuwait (NK) Fields. North Kuwait Fields is located approximately 90kms from north of Kuwait city. The purpose of this project is to provide sufficient injection water to meet the requirements of the north Kuwait well injectors. For this, an effluent water treatment and injection plant shall be built in a location between the SABRIYAH and RAUDATAIN fields of north Kuwait having a treatment design capacity of 1,045,000 BWPD with 550,000 BWPD for injection and balance 495,000 BWPD will be transferred to existing central processing injector facility (CIPF existing). The plant shall receive a continuous supply of effluent water from existing Gathering Centers GC-15, GC-23, GC-24, GC-25 and an intermittent supply of effluent water from new GC-29, GC-30 and GC-31 (all routed from existing CIPF). For this purpose, the COMPANY has entered into a contract with DODSAL ENGINEERING

&

CONSTRUCTION

PTE

LIMITED,

hereafter

referred

as

CONTRACTOR, for Engineering, Procurement, Construction and Related Activities, with a Contract No. 14050642.

2.

OBJECTIVE The objective of this document is to define the relevant pipeline design data, general philosophies, design criteria, methodology, relevant codes and standard and other important considerations to be adopted for the detailed engineering of the pipelines involved for New EWTIP project.

3.

PROJECT DESCRIPTION The purpose of this project is to provide sufficient injection water to meet the requirements of the North Kuwait well injectors. To this end, the EW Treatment and Injection Plant (NK) (EWTIP) will be located between the Sabriyah and Raudatain fields. 510 MBWPD EW injection facilities for injecting water into 51 no of wells (550 MBWPD Water Injection Pipelines Distribution System up to Manifolds). The EWTIP

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EFFLUENT WATER TREATMENT AND INJECTION PLANT (NK) Project No. EF/1761 Class 1


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treatment system is divided into two identical trains each designed to treat 522.5 MBWPD. The plant includes collection tanks that receive effluent water from: • GC-15 (200 MBWPD normal; 220 MBWPD design) • GC-25 (200 MBWPD normal; 220 MBWPD design) • GC-23 (150 MBWPD normal; 165 MBWPD design) • GC-24 (200 MBWPD normal; 220 MBWPD design) • GC-29 (240 MBWPD design) • GC-30 (240 MBWPD design) • GC-31 (240 MBWPD design)

Collected effluent water from GCs is treated in the EW treatment facility to meet the required quality specification for injection. Prior to injection, the treated water is stored in the Treated Water Tanks. These tanks may also receive effluent water from GC-29, GC30 and GC-31 to maintain the required amount of injection water, should one of the primary source GCs be shut down. A portion of the treated effluent water is also to be transferred from the treatment plant to the effluent water collection tank of the CIPF (EF/1071, Effluent Water Injection Plant, Phase I). To minimize the size of the Treated Water Tanks and eliminate the need to install new dedicated treated effluent water transfer pumps, this treated water is pumped directly from the outlet of the new effluent water treatment plant upstream of the Treated Water Tanks. Inline Booster and High Pressure (HP) Injection Pumps are capable of maintaining a minimum operating pressure of 255 barg (3700 psig) at the inlet of farthest injector wellhead along with injection headers and injection lines to injection wells.

4.

SCOPE OF THIS DOCUMENT The scope of this document is to define the design criteria for the permanent works relevant to this project like pipeline engineering design data, analysis methods and design methods to be used for detail engineering of pipeline sections. The CONTRACTOR shall design and install all pipelines as indicated on the P&ID’s up to the interfaces and Tie-Ins to existing pipework. Refer to Drawing Number


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14050642-0100-PL-DWG-0001: Schematic of Interconnecting Pipework for an overall view of the Pipeline and Off-Sites Works. The new Pipelines will connect and transport the various products between GC-15, GC-23, GC-24, GC-25, GC-29, GC-30 and GC-31, Fuel Gas Headers, Recovered oil headers, Brackish Water Header, Treated Water distribution header, Treated Water Manifold, Wellhead Flow Lines, EWTIP, CIPF, B.S-131, B.S-132 & various tie-ins to existing pipeline in North Kuwait. Refer to the Schematic & Layout represented in Figure-1 shows the overall view of the Pipeline and Off-site works. The pipelines are required for the following services:  Effluent Water  Treated Water  Fuel Gas  Recovered Oil  Brackish Water (Fire Water)  Injection Water.

5.

TERMINOLOGY For the purpose of this document, the words and abbreviations listed below shall have the explanations as follows:

5.1.

DEFINITIONS COMPANY CONTRACTOR

Kuwait Oil Company (K.S.C) EPC Contractor nominated to carry out the project, Dodsal Engineering and Construction Pte Ltd.

PROJECT

Works related to contract no: 14050642.

WORK

Activities required to be completed by the CONTRACTOR

SHALL

The word “SHALL” is understood to be mandatory to comply with the requirements.


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SHOULD

5.2.

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The word “SHOULD” is understood to be strongly recommended to comply with the requirements.

ABBREVIATIONS API

American Petroleum Institute

ASME

American Society of Mechanical Engineers

ASTM

American Society for Testing and Materials

BS

British Standard

EWTIP

Effluent Water & Treatment Injection Plant

CIPF

Central Injection Pumping Facilities

B.S

Booster Station

GC

Gathering Centres

CA

Corrosion Allowance

CP

Cathodic Protection

DF

Design Factor

KM

Kilo meters

FEED

Front End Engineering Design

FG

Fuel Gas

ROW

Right of Way

SMYS

Specified Minimum Yield Strength

HSAW / SSAW

Helical or Spiral Submerged Arc Weld

LSAW

Longitudinal Submerged Arc Weld

LP

Low Pressure

MBOPD

Thousand U.S Barrels of Oil Per Day

MSS

Manufacturers Standardization Society

NACE

National Association of Corrosion Engineers

SMLS

Seamless

TCP

Temporary Cathodic Protection


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CS

Carbon Steel

P&ID

Piping & Instrumentation Diagram

RTRP

Reinforced Thermosetting Resin Pipe

HDPE

High Density Poly Ethylene

FBE

Fusion Bonded Epoxy

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DESIGN CODES, SPECIFICATIONS AND STANDARDS

All detailed design and construction shall be performed to COMPANY Specifications, Standards, and International Codes and to other documents listed in this Basis of Design Document. In particular, reference should be made to Company Specification and its Addendum to 015-IH-1002: Pipeline Design, Appendix-F: Technical specification and KOC-L-002: KOC Recommended Practice for the Protection of KOC Services. All pipelines shall be designed in accordance with ASME B31.4/ ASME B31.8 as applicable to respective services. In common, the pipelines and related facilities shall confirm in design, materials and performance except where specified, with the current issue and amendments prevailing on the effective date of contract.

6.1. INTERNATIONAL CODES AND STANDARDS

AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME)

ASME B16.5

Pipe Flanges and Flanged Fittings

ASME B16.9

Factory Made Wrought Steel Butt welding Fittings

ASME B16.10

ASME B 16.20

Face to Face and End to End – Dimensions of Valves Metallic Gaskets for Pipe Flanges (Ring-Joint, Spiral-Wound and Jacketed)


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ASME B 16.21

Non-metallic Flat Gaskets for Pipe Flanges

ASME B 16.25

Butt-Welding Ends

ASME B 16.34

Valves – Flanged, Threaded and Welding End

ASME B16.47 ASME B 16.48 ASME B 16.49

ASME B 31.4

ASME B 31.8

Large Diameter Steel Flanges NPS 26 through NPS 60 Line Blanks Factory-made wrought Butt-welding induction Bends for transportation & distribution system Pipeline Transportation Systems for Liquid Hydrocarbons and Other Liquids Gas Transmissions and Distribution Piping Systems

ASME B 31.3

Process Piping

ASME B 46.1

Surface texture

Section VIII - Boiler and Pressure Vessel Code Section II Div. 1 Part A – Ferrous material ASME

specifications Section II Div. 1 Part D – Properties (Materials) Section V – Non Destructive Examination Section VIII Div. 1 - Pressure Vessels Section IX – Welding and brazing Qualifications

AMERICAN PETROLEUM INSTITUTE (API)

API 5L

Specification for Line Pipe (45th Edition)

API 6D

Specification for Pipeline Valves

API 6F

Specification for Fire test for valves


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CONTRACT NO. 14050642 PIPELINE DESIGN BASIS Doc. No. : 14050642-100-PL-DBM-0001 Recommended API RP 1102

Practice

for

Liquid

13 of 54 1 19.06.2016 Petroleum

Pipelines Crossing Railroads and Highways (7th Edition)

API STD 1104 API RP 1109 API RP 1110

Standard

for

welding

Pipelines

and

related

Facilities (20th Edition) Marking Liquid Petroleum Pipeline Facilities Recommended Practice for the Pressure Testing of Steel Pipelines (5th Edition)

American Society for Testing and Materials (ASTM):

Standard Specification for Carbon and Alloy Steel ASTM A 694 / M

Forgings for Pipe Flanges, Fittings, Valves and Parts for High Pressure Transmission Service

ASTM E 94 ASTM E 165 ASTM E 709

Standard Guide for Radiographic Examination Standard Test Method for Liquid Penetrant Examination Standard Guide for Magnetic Particle Examination Standard Practice for Design, Manufacture and

ASTM E 747

Material Grouping Classification of Wire Image Quality Indicators (IQI) Used for Radiology

American Welding Society (AWS):

AWS A 2.4

AWS A 5.5 / M

Standard Symbols for Welding, Brazing and Non-Destructive Examination Specification for Low Alloy Steel Electrodes for Shielded Metal Arc Welding



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British Standards (BS): Industrial Valves Face-to-Face and Centre-to-Face BS EN 558

Dimensions of Metal Valves for use in Flanged Piping Systems Welding Recommendations for Welding of Metallic

BS EN 1011

Materials Part 1: General Guidance for Arc Welding Part 2: Arc Welding of Ferrite Steels

BS EN 1759

Flanges and their Joints – Circular Flanges for Pipes, Valves, Fittings and their Accessories Methods of Tests for Paints: Part F 11: Determination

BS 3900

of Resistance to Cathodic Disbonding of Coatings for use on Land Based Buried Structures

BS 5930

Code of Practice for Site Investigations

BS 6031

Code of Practice for Earthworks

BS EN ISO 6507

Metallic Materials – Vickers Hardness Test

BS PD 6513

Magnetic Particle Flaw Detection

BS 7361

BS PD 8010

BS 8110

BS EN ISO 17292

Cathodic Protection Part 1 – Code of Practice for Land and Marine Applications Code of Practice for Pipelines Part 1: Steel Pipelines on Land Structural Use of Concrete Metal Ball Valves for Petroleum, Petrochemical and Allied Industries



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International Standards Organization (ISO):

Petroleum and Natural Gas Industries – Cathodic ISO 15589

Protection of Pipeline Transportation Systems Part 1: On-Land Pipelines.

Manufacturers Standardization Society of the Valve and Fittings Industry (MSS): Standard Finishes for Contact Faces of MSS SP-6

Pipe Flanges Connecting Ends of Flanges of Valves and Fittings

MSS SP-25

MSS SP-44

Marking Systems for Valves, Fittings, Flanges and Unions Steel Pipe Flanges Quality Standard for Steel Casting and Forging for

MSS SP-53

Valves, Flanges and Fittings and Other Piping Components – Magnetic Particle Examination Method Quality Standard for Steel Castings for Valves,

MSS SP-55

Flanges and Fittings and Other Piping Components – Visual Method for Evaluation of Surface Irregularities

MSS SP-72

MSS SP-75

Ball Valves with Flanged or Butt Welding Ends for General Service Specification for High Test Wrought Butt Welding Fittings Integrally Reinforced Forged Branch Outlet

MSS SP-97

Fittings – Socket Welding, Threaded, and Buttwelding Ends.



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National Association of Corrosion Engineers International (NACE): Petroleum and Natural Gas Industries -Materials for use NACE MR 0175 /

in H2S-containing environments in Oil and Gas

ISO 15156

production: Parts 1 to 3 (2009 & its latest technical circulars)

NACE SP 0177

Mitigation of Alternating Current and Lightning Effects on Metallic Structures and Corrosion Control Systems Laboratory Testing of Metals for Resistance to

NACE TM 0177

Sulfide Stress Cracking and Stress Corrosion Cracking in H2S Environments

NACE RP 0274

NACE TM 0284

NACE SP 0286

High Voltage Electrical Inspection of Pipeline Coatings Evaluation of Pipeline and Pressure Vessel Steels for Resistance to Hydrogen-Induced Cracking Electrical Isolation of Catholically Protected Pipelines Methods and Controls to Prevent In-Service

NACE RP 0472

Environmental Cracking of Carbon Steel Weldments in Corrosive Petroleum Refining Environments.

NACE SP 0169 NACE SP 0200 NACE SP 0502

NACE SP 0572

Control of External Corrosion on Underground submerged piping systems Steel Cased Pipeline Practices Pipeline External Corrosion Direct Assessment Methodology Design, Installation, Operation and Maintenance of Impressed current deep Anode Beds



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6.2. PROJECT REFERENCE SPECIFICATION / ADDENDUMS / DRAWINGS / DOCUMENTS: KOC Specifications: 015-IH-1001 Rev.1

Pipeline Construction

015-IH-1002 Rev.1

Pipeline Design

015-IH-1004 Rev.1

Pipeline Pigging and Hydrostatic test

015-IH-1005 Rev.1

Pipeline Dewatering, drying and Purging

015-IH-1008 Rev.1

Pipeline Field Welding Non Sour Service

015-IH-1009 Rev.1

Flow lines

015-LH-1002 Rev.1

Piping design

015-PH-1910 Rev.1

Cathodic Protection (CP) Transformer Rectifier Units

015-SH-1006 Rev.1

Topographical Survey

015-WH-1001 Rev.0

Welding Procedure Approval and Welding Quality Requirement

015-WH-1002 Rev.0

Field Welding Requirements including: welding, Heat treatment and NDT of piping

015-WH-1006 Rev.1

Cathodic Protection Design Requirements

Document No.

Description

KOC-L-002 Rev.3

RP for Protection of KOC Services

KOC-L-012 Rev.1

Cathodic Protection Material

KOC-L-015 Rev.2

External Cathodic Protection of Underground Steel Pipeline and Piping Networks

KOC-MP-005 Rev.1

Pipeline Pig Trap Systems

KOC-MP-010 Rev.1

Piping Material Classes


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KOC-MP-011- Part-1 Rev.2 KOC-MP-011- Part-2 Rev.2

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RTRP Pipes and Fittings Materials RP for RTRP Pipes and Fittings, Engineering Design and Installation.

KOC-MP-018 Rev.1

Seamless Line Pipe to API 5L

KOC-MP-019 Rev.1

Submerged Arc Welded (SAW) Pipe to API 5L

KOC-MP-033 Part-1 Rev.1

KOC Standard for Valves: Part 1- Ball Valves

KOC-MP-015 Rev.1

KOC Standard for Check Valves

KOC-MP-013 Rev.1

KOC Standard for Gate Valves

KOC-MP-023 Rev.1

KOC Standard for Through-Conduit Gate Valves

KOC-MP-014 Rev.1

KOC Standard for Globe Valves

KOC-MP-035 Rev.1 KOC-MP-038 Rev.2 KOC-MS-001 Part-1 Rev.2

Internal Corrosion Monitoring Equipment for Facilities and Pipelines Hot Tapping and plugging Material Specification For Line Pipe For Sour Service

KOC-MS-002 Rev.1

Material Specification For Induction Bend

KOC-P-001 Rev.3

Painting and Coating of External Metal Surface

KOC-P-004

External Coating Of Pipelines – Dual Layer FBE

Part-4 Rev.2 KOC-P-004 Part-7 Rev.2

Coating of Field Girth Welds, Fittings and Flanges

KOC-P-005 Rev.1

Internal Coating of Pipelines

55-04-72 Rev.0

Typical Barred Tee Details

EWTIP-00-GE-BOD-0001 Rev.5

Basis of Design

EWTIP-20-PL-SPC-0001

ADDENDUM TO KOC SPECIFICATION:

Rev.0

TOPOGRAPHICAL SURVEY (015-SH-1006)

1


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EWTIP-20-PL-SPC-0002 Rev.1



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ADDENDUM TO KOC SPECIFICATION: PIPELINE DESIGN (015-IH-1002 REV1)

ADDENDUM TO KOC SPECIFICATION: FLOWLINES (015-IH-1009 REV2) SPECIAL CRITERIA TO KOC STANDARD FOR EXTERNAL COATING OF PIPELINES PART 4 FUSION BONDED EPOXY COATING (KOC-P004 PART4 REV2)


ADDENDUM TO KOC SPECIFICATION PIG LAUNCHERS/RECEIVERS (015-IH-1006 REV1)


SPECIAL CRITERIA TO KOC STANDARD FOR

Rev.0

INTERNAL COATING OF PIPELINES (KOC-P005 REV1)


SPECIAL CRITERIA TO KOC STANDARD FOR EXTERNAL COATING OF UNDERGROUND PIPING/PIPELINES - HIGH BUILD EPOXY COATING (KOC-P-004 PART8 REV1) SPECIAL CRITERIA TO KOC RECOMMENDED


PRACTICE FOR THE PROTECTION OF KOC SERVICES: CLEARANCE REQUIREMENTS FOR BURIED PIPELINES, CABLES, UNDERGROUND STRUCTURES, BUILDINGS AND HOUSING PROJECTS (KOC-L-002 REV3) SPECIAL CRITERIA TO KOC STANDARD FOR


EXTERNAL COATING OF UNDERGROUND

Rev.0

PIPING/PIPELINES - HIGH BUILD POLYURETHANE COATING (KOC-P-004 PART9 REV1)


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SPECIFICATION FOR HIGH DENSITY

Rev.1

POLYETHYLENE (HDPE) LINERS FOR

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CARBON STEEL PIPELINES EWTIP-20-PL-SPC-0011

SPECIFIC CRITERIA TO KOC STANDARD FOR

Rev.1

ELECTRIC WELDED PIPES (KOC-MP-017 REV1)


PIPELINE LEAK DETECTION SPECIFICATION


Special Criteria To Standard For Seamless Line

Rev.0

Pipe to API 5L ( KOC-MP-018 Rev.1)


Criteria To Standard For Submerged Arc Welded

Rev.0

(SAW) Pipe to API 5L ( KOC-MP-019 Rev.1)


ADDENDUM TO KOC SPECIFICATION:

Rev.0

PIPELINE PIGGING AND HYDROSTATIC TEST (015-IH-1004 REV1)


ADDENDUM TO KOC SPECIFICATION

Rev.0

PIPELINE DEWATERING, DRYING AND PURGING (015-IH-1005 REV1)


Project Specific Criteria to Material Specification

Rev.1

For Induction Bend (KOC-MS-002 Rev.1)


Addendum to Specification for Pipeline

Rev.1

Construction ( 015-IH-1001 Rev.1)


PROJECT SPECIFIC CRITERIA FOR KOC RECOMMENDED PRACTICE FOR EXTERNAL CATHODIC PROTECTION OF UNDERGROUND STEEL PIPELINES & PIPING NETWORKS

6.3. ORDER OF DOCUMENT PRECEDENCE In case of conflict on technical requirements, the most stringent requirements as defined by the company shall apply as per clause no 1.2 and 3.3 of Appendix-F of the contract.


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In case of conflict on codes, standards, company specifications, regulatory requirements, following order of precedence shall apply: a. Regulatory Requirements b. Addendum and project specific criteria to KOC specifications and standards c. KOC standards & Specifications d. International Codes and Standards Should there be an inconsistency, conflict or discrepancy between any of the Standards, Specifications or Regulatory requirements, the most stringent and safest requirement applicable to the project shall prevail to the extent of the inconsistency, conflict or discrepancy. Any inconsistencies critical to the design shall be brought to the attention of KOC for resolution.

7.

GENERAL DESIGN DATA 7.1. BATTERY LIMIT The design battery limit between pipeline and piping are the flanges at the launcher / receiver and before first isolation valve on the bypass line near barred tee & the code break between ASME B 31.3 and ASME B 31.8 / ASME B31.4 as per P & ID.

7.2. UNITS OF MEASUREMENT SI units shall be used for all calculations and on all drawings. For convenience, data in imperial units may be included for reference.

Design Unit Standards(Note 1) Item

SI units

Imperial Units

Oil Flow

m3/hr.

bbl/d

Gas Flow

MMm3/d

MMscf/d

Density

kg/m3

lbs./ft3

Pressure

bar(a) or bar(g)

psia or psig

Differential Pressure

bar/mbar

psi

Temperature

°C

°F



Class 1

Viscosity

MPa

cP

Kinematic Viscosity

cSt

cSt

Mass

kg

lbs

mm

inch

Energy

MJ

Btu

Power

kW

hp

Pipe diameters, valve size, instrument tubing (note 2)

Seconds, hours,

Time

days

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Seconds, hours, days

Piping (note 2), Structural, Isometric, Site (Layouts, Topographical etc.), and

Metric

English

Metric

English

Metric

English

Vendor Drawings Vessel Dimensions Electrical Equipment Cabinets & other equipment inside control buildings Notes: 1. Standard conditions are defined as 14.696 psia and 60°F (1.01325 bar(a) and 15°C) 2. All piping and tubing to be SI sizes.

7.3. COORDINATE SYSTEM

The co-ordinate system to be used for mapping on the project shall be: Projection

:

Universal Transverse Mercator

Zone

:

UTM 38R

Datum

:

World Geodetic System (WGS-84)


8.

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SITE CONDITION & DESIGN DATA

8.1. SITE CONDITION / ENVIRONMENT DATA The site conditions shall be in accordance with CL.5.0 of project Basic Design Data KOC-G-007 R4.

UNDERGROUND TEMPERATURE As per clause 5.1.5 of KOC-G-007, soil temperature at 1.22m depth: Minimum (Soil)

:

17 °C

Maximum (Soil)

:

35 °C

Minimum (Ambient)

:

- 3 °C

Maximum (Ambient)

:

55 °C

Maximum

:

100%

Minimum

:

6%

ABOVE GROUND TEMPERATURE

RELATIVE HUMIDITY AT 55° C

LOCAL CONTAMINATION (as per KOC-G-007) Lighting

:

To be considered

Seismic Factor

:

Rainfall

:

Frosts

:

Never

Snow

:

Never

Sand Storms

:

Strong frequent sandstorms are common between march & may

Wind speed

:

45 m/s at above ground

Zone-1; Zone factor (Z)=0.075; site co-efficient = 1.0 to 1.2 Annual rainfall is 200mm maximum.

8.2. BASIC DESIGN DATA The FEED study drawings of pipelines and pipeline facilities: 

P&ID of all pipeline systems.



Plot plans for launcher / receiver scrapper facilities at EWTIP, Fuel gas tie-in, Recovered Oil return at GC-15 and GC-25, all manifolds.



Class 1



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Field maps showing injection well locations and pipeline routings used in the FEED study.



Alignment sheets for produced water pipelines, injection water trunk lines and the recovered oil pipelines.



Schematics of the high pressure pipelines used for hydraulic simulations and materials quantity determination.

8.3. PIPELINE CATEGORIES The pipeline categories shall comply with the requirements of KOC specification: Application of codes and Group Standards, which has been reproduced for design purpose as in below table, Table 8.1 : Pipeline Categories Approx. S.No.

Applicable Project Pipelines

Length (KM)

1

20” RTRP Pipeline from GC-15 in CIPF to EWTIP

1.72

2


1.73

3


1.72

4


1.72

5

6” CS Pipeline from B.S-131 to EWTIP (2 nos.)

6

7

20” CS HDPE lined Pipeline from EWTIP to Sabriyah manifold distribution 20” CS HDPE lined Pipeline from EWTIP to Rudatain manifold distribution

17 (8.5 each) 47.0

16.4

Product

Design

type

Code

Effluent

ASME

Water

B31.4

Effluent

ASME

Water

B31.4

Effluent

ASME

Water

B31.4

Effluent

ASME

Water

B31.4

Fuel Gas

ASME B31.8

Injection

ASME

Water

B31.4

Injection

ASME

Water

B31.4

1


8

9

10

11

12

13

14

15

Page Rev Date

CONTRACT NO. 14050642 PIPELINE DESIGN BASIS Doc. No. : 14050642-100-PL-DBM-0001 14” CS HDPE lined Pipeline from Distribution header to Sabriyah manifolds (3 nos.) 12” CS HDPE lined Pipeline from Distribution header to Sabriyah manifold (1 no.) 10” CS HDPE lined Pipeline from Distribution header to Sabriyah manifolds (3 nos.) 10” CS HDPE lined Pipeline from Distribution header to Raudatain manifolds (3 nos.) 10” CS HDPE lined Flowline from Sabriyah manifolds to Well heads (1 no.) 8” CS HDPE lined Flowlines from Sabriyah manifolds to Well heads (11 nos.) 6” CS HDPE lined Flowlines from Sabriyah manifolds to Well heads (23 nos.) 8” CS HDPE lined Flowline from Raudatain manifolds to Well heads (8 nos.)

2.521

0.384

3.364

1.897

3.83

65.525

61.5

45.03

16

6” CS HDPE lined Flowlines from Raudatain manifolds to Well heads (8 nos.)

21.39

17

30” RTRP Pipeline from EWTIP to CIPF Existing

1.72

18

12” RTRP pipeline from B.S-132 to EWTIP

3.1

19

6” CS FBE Lined pipeline from EWTIP to GC-15 & GC-25 (2 Nos.)

23.605

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Injection

ASME

Water

B31.4

Injection

ASME

Water

B31.4

Injection

ASME

Water

B31.4

Injection

ASME

Water

B31.4

Injection

ASME

Water

B31.4

Injection

ASME

Water

B31.4

Injection

ASME

Water

B31.4

Injection

ASME

Water

B31.4

Injection

ASME

Water

B31.4

Treated

ASME

Water

B31.4

Brackish

ASME

Water

B31.4

Recovere

ASME

d Oil

B31.4

Total Length 321.156

8.4. DESIGN LIFE SPAN The facilities have been designed for a life of 25 years. Should it be impractical for a component to be designed with this life expectancy, a review with KOC shall be conducted and the outcome documented.

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8.5. PIPELINE TEMPERATURE & PRESSURE

Table 8.2: Temperature and Pressure Design

Operating

Design

Operating

Pressure

Pressure

Temperature

(barg)

(barg)

(°C)*

Distribution Lines

278

331

30-60

-3 / 93

Flow Lines

278

331

30-60

-3 / 93

5.9

11

30-60

-3 / 93

25.5

46

30-60

-3 / 93

4

15

30-60

-3 / 93

Oily Water

8.41

10.5

30-60

-3 / 93

Brackish Water

4.13

15

30-60

-3 / 93

Pipelines

Temperature UG / AG (°C)

Treated Water Return Line to CIPF (existing 1071) Fuel Gas Effluent Water

8.6. PIPELINE FLANGE RATING PHILOSOPHY For the selected material class, the flange rating shall be selected by applying the chosen design pressure and temperature in the appropriate rating table in the Piping Material specification and shall in accordance to ASME B 16.5 & ASME 16.47.

Pipeline

Flange Rating

Effluent water

150 #

Recovered Oil

300 #

Fuel Gas

300 #

Brackish Water

300 #

1

1


9.

CONTRACT NO. 14050642 PIPELINE DESIGN BASIS Doc. No. : 14050642-100-PL-DBM-0001 Treated Water

150 #

Injection Water

2500 #

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PIPELINE MATERIALS 9.1. GENERAL Pipelines such as Injection water, Recovered oil & Fuel Gas shall be designed & constructed from carbon steel material in accordance with API 5L and COMPANY design specifications listed in CL.6.2 of this document.

Brackish water, Treated water & Effluent water pipelines shall be designed & constructed from Reinforced Thermosetting Resin Pipe (RTRP) in accordance with ASTM D2996 and COMPANY design specifications listed in CL.6.2 of this document.

All carbon steel materials shall be suitable for sour service conforming to KOCMS-001 Part 1, NACE MR 0175 / ISO 15156 and shall be HIC tested. Testing shall be performed using Test Solution “A” as per NACE Standard TM-0284. Size of any branch or instrument connections on Pipeline which are exposed to service shall not be less than 2 inch for mechanical strength reasons.

9.2. LINE PIPE Carbon Steel Seamless Line pipe shall be used for fuel gas, Injection water and Recovered Oil services. Seamless line pipe shall conform to specification level 2 (PSL 2) of API 5L Specification 45th Edition and the requirements of KOC-MS-001 and Project Criteria for sour service conditions as specified in the pipeline data sheet 14050642-100-PL-DAT-0001. The final material grade and wall thickness shall be confirmed and submitted by CONTRACTOR to COMPANY for their approval. For Injection pipelines, carbon steel pipe with HDPE internal liner shall be used for underground section and carbon steel pipe with Incoloy 825 internal liner shall be used for aboveground section. The connection of these two pipeline sections shall have suitable flanged arrangements as per approved


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manufacturer’s design. For mechanical handling considerations and to avoid pipe damage during construction the pipe diameter to wall thickness ratio should not exceed 96 in general as per clause 403.2.5 of ASME B31.4. All carbon steel pipes of API 5L X60 material shall be of SMLS construction up to 20 inch. Pipe material shall be Reinforced Thermosetting Resin Pipe (RTRP) for Effluent Water, Treated water and Brackish Water and pipe shall be manufactured by Dual Helical Filament Winding Process in accordance with COMPANY standard for RTRP pipes and fittings: KOC-MP-011 Part 1.

9.3. CARBON STEEL PIPE DESIGN PROPERTIES The properties shown in table below are to be used for calculations involving carbon steel line pipe with reference to API 5L, 45th Edition. Table 9.1: Pipeline Design Properties Property

Units

Material API 5L, 45th

All CS Pipelines in Table 8.1

Edition Material grade Yield strength Min SMYS Yield strength Max Ultimate Tensile Strength

Pipeline

L415 (X60) MPa

MPa

MPa

L245 (B)

415

245

565

450

520

415

Density

Kg/m3

7850

Young’s’ Modulus

MPa

203000

mm /

11.7 x 10-6

Thermal Co-efficient of Expansion


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mm /C



Poisson’s Ratio

0.3

9.4. RTRP PIPE DESIGN PROPERTIES The properties shown in table below shall be given to vendor for the RTRP Line pipes with reference to ASTM D 2996 Table 9.2: Pipeline Design Properties Property

Units

Resin Type Epoxy Resin

Polyester & Vinyl Ester Resin

Tensile Strength

103 psi

4-13

6-13

Tensile Modulus

106 psi

0.35

0.3 – 0.64

Elongation at Break

%

3-15

<2

Flexural Strength

103 psi

13-21

8.5-23

1.11 – 1.40

1.1 – 1.46

Specific Gravity

9.5. BRANCH CONNECTIONS For all pipeline pig trap nozzle fittings, the thickness shall be as per the adjoining B31.3 piping class, however the material grade of the branch fitting shall be the same as the pipeline.

9.6. RTRP PIPE JOINTS The RTRP pipe joint methods shall be as follows: Taper-Taper adhesive bonded pipes & fittings joints

1


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The RTRP piping shall be joined adopting most appropriate joining method(s) based on design conditions, service fluid & pipe size. The manufacturer shall suggest and recommend the most appropriate joining method(s) to contractor based on KOC standards well ahead of the start of the project for review & approval. The jointing method shall be in accordance with CL.10. of KOC design specification KOC-MP-011 part-2. Flanged Joints shall be used at the transition points of RTRP pipes to Steel pipes.

9.7. MATERIAL CERTIFICATION The specific requirements for documentation and certification of all materials and equipment to be procured are included in the individual Project technical Specifications or Material Requisition. 10.

PIPELINE FITTINGS The material used shall satisfy the requirements of NACE MR 0175 / ISO 15156 where applicable, pipeline fittings shall be ASTM, ANSI / ASME, API and other international standards as applicable. Dimensional standards i.e. tolerance, in general, shall be as per the relevant code. The final material grade and wall thickness shall be confirmed. Factors to be considered include ASME B31.4 / B31.8 requirements as applicable, KOC specifications and contract specific requirements. All butt welded fittings shall comply with ANSI B16.9. RTRP fittings shall be in accordance with KOC standard for RTRP pipes and fittings, KOC-MP-011 Part 1 and Part 2.

10.1. PIPELINE BENDS 10.1.1 GENERAL The use of Cold Field bends and hot induction bends shall be avoided and wherever possible bends shall be formed by bending pipe with its elastic limits



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(i.e. elastic bends) and shall be formed using a minimum radius arrived as per thickness calculation. Cold Field bends and hot induction bends shall only be considered where the use of elastic bends is not feasible, (e.g. sag bends immediately downstream of pig receivers). Only Seamless line pipe shall be used for cold field or hot induction bends. Prefabricated i.e. miter or segmented bends are not allowed. Bend radius for Pipeline bends to comply with the requirements in Table 10.1. Minimum bend radii are to be determined by suitability for passage for intelligent pigs, inspection pigs and by the bending process. Hot induction bends to be formed from the line pipe, subject to an allowance on the mother pipe for thinning during bending. Cold Field Bends to conform to requirements of Pipeline Construction Specification.

Pipeline bends shall accommodate the passage of pigging and inspection devices. The wall thickness at all locations on finished bends shall be no less than the required design thickness including corrosion allowance, where applicable. Wall thickness shall be selected to meet the design requirement and give adequate performance in construction handling, bending and welding.

Table 10.1 Pipeline Bends Condition

Pipe Diameter

Bend Radius

Hot induction Bends

All Sizes

5 D*

Cold field Bends

All Sizes

40 D*

* D is the pipeline outside diameter.

1

10.1.2 ELASTIC BENDS Change in direction wherever possible shall be made using elastic bends as per clause 9.2.2 of 015-IH-1002.


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10.1.3 COLD FIELD BENDS Cold field bends may be used at locations of horizontal or vertical changes in direction. Miter or “lobster-back” bends shall not be used. Cold field bends shall have a minimum bending radius of 40D, where D is the pipeline outside diameter. Cold field bends shall be in accordance to Cl.9.2.1 of 15-IH-1002. 10.1.4 HOT INDUCTION BENDS All bends shall be produced by induction bending. Bend radius shall be 5D (where D is the pipe OD). All the bends shall be supplied with straight tangent ends at least 500 mm in length. Induction Bends shall be manufactured in accordance with COMPANY specification KOC-MS-002 and addendum EWTIP-20-PL-SPC-0017. Hot bends shall be in accordance to Cl.9.2.3 of 15IH-1002.

10.2. BARRED TEE Barred tees shall be installed in piggable lines where pipeline branch connections of 25% and above of main pipeline diameter are required. Barred tees shall be manufactured to a proven design that shall allow the smooth passage of pigging tools without the risk of snagging or deflection. All barred tees shall comply with the requirements of ASME B16.9/ MSS-SP-75 and also to sour service conditions. Barred Tees shall be formed extruded outlet, integral type and meeting the design code requirements of the existing header pipe.

10.3. INSULATING FLANGE JOINTS / INSULATION GASKET KIT Insulating flange joints shall be installed at each end of the pipeline to electrically isolate the buried pipeline cathodic protection system from the above ground station pipe work. All insulating flange joints shall be installed above ground (not buried).

10.4. PIG LAUNCHER/RECEIVER Pig launchers and receivers shall be designed for the same service conditions



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as the pipeline. The barrel shall be of sufficient length to accommodate an intelligent inspection tool. All materials shall be for sour service and resistance to HIC in accordance with NACE MR 0175/ISO 15156, where applicable. Pig launcher/ receiver shall be capable of handling intelligent pigs and other cleaning pigs. The launcher and receiver barrels shall be designed in accordance with the requirements of ASME B 31.4 / B 31.8 and KOC standard KOC-MP-005 and its end closure shall be designed and fabricated according to ASME section VIII, Div.1 section UG-35.2 with fail safe design. End closures shall also have a pressure –locking device to prevent opening of the door when the trap is pressurized and also a safety bleed that when released will alert the operator .The barrel of the pig traps shall be designed to accommodate the latest intelligent inspection tool. The pig traps shall be Bi-directional and to sour service conditions. Adequate arrangements for launching, retraction, handling and lifting of cleaning and instrumented pigs shall be provided at the scraper stations. Traps shall be accessible by walkway/ road for movement of equipment, pigs etc. The diameter of barrel of the scraper shall be as per project data sheet. Center line elevation of scraper trap shall be at suitable height from grade level. Suitable arrangements shall be provided for handling and lifting of pigs. Individual drain lines shall be provided that discharges into the dedicated sumps. Pig handling facility shall comprise provision of a trolley with a push rod and pulling line to assist loading or removal of pigs from the traps. All moving and mating parts shall be provided with non-sparking materials. Permanent pigging systems shall be installed on high-pressure injection header, recovered oil and fuel gas pipelines. All distribution manifold lines and injection well flow lines shall have provision to install Mobile Pig Launcher / Receiver. For Mobile Pig Trap, All associated skid piping & instrumentation and all spool pieces/ blind flanges shall be provided as per P&ID.

Pipeline pigging shall be carried out in accordance with KOC standard 015-IH-



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1004, rev.1 and EWTIP-20-PL-0015, rev.0.

10.5. PIG SIGNALLERS Pig signallers shall be located on pig launchers / receiver facilities on pipeline system to monitor the passage of pigs. Details of the required facilities shall be as per relevant P&IDs. Pig signallers shall be bi-directional ultrasonic flanged intrusive type with a trigger penetrating into the main bore of the pipe which will be moved by the passing pig and a mechanical indicator mounted externally on the pressure housing. They shall be mounted vertically on top of the pipe with two x 2-in NB isolation ball valves to isolate the pig signaller from the pipeline. Pig signaller isolation ball valves shall be full bore and end connections shall be as per piping class. A portable jacking tool for removing the unit whilst the pipeline is under pressure shall be provided.

10.6. PIPELINE ANCHORS Full thrust anchors shall be installed at both ends of the various pipeline at the transition where the pipeline changes from buried to above ground before the permanent pig launcher/ receiver and as per the results of the Pipeline Stress Analysis. Calculations shall be performed to design the anchors, anchor flanges and concrete blocks of reinforcement. Stress induced at the pipeline transition point shall be calculated and verified for no failure.

10.7. FLANGES, BRANCH CONNECTIONS AND FITTINGS Threaded connections (Pipe to pipe, fittings), slip-on flanges and miter connections shall not be used in any part of the pipeline system. “Pup” pieces shall not be less than 300mm length or one pipe diameter whichever is greater. For mechanical strength reasons, there shall be no branch or instrument connections smaller than DN 50 mm (2”) on the pipeline which are exposed to service. Gaskets for flanged connections shall be as per project specification for the relevant pressure class. The number of flanged connections in the



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pipeline systems shall be minimized and all flanged connections shall be above ground except the flange joints for HDPE lined pipelines / flowlines. Bolt tightening for flanges of DN 200 mm (8”) and above shall be by means of hydraulic bolt tensioning equipment using an approved tensioning procedure. Due allowance on the overall stud bolt length shall be made for this provision.

10.8. VALVES Mainline valves shall be full bore ball valves as per relevant P&ID and data sheets, to allow unhindered passage of pigs. All pipeline ball valves (4” and above sizes) shall be trunnion mounted ball valves complying to API 6D for the diameter of the pipelines for which they are installed and shall be full bore with double block and bleed facilities to monitor seal condition. Valves in underground pipeline shall be located in a valve pit and valve pit details shall be as per KOC drawing 55-02-39. Sectionalizing valves are not required on the routes of the various pipelines for isolation purpose but are required at the pig launchers/receivers and Manifold facilities, if required by company. All full bore ball valves shall confirm to NACE MR0175/ISO 15156. Valves requiring motor / pneumatic / hydraulic operation shall be in accordance with the P&IDs. All pipelines shall have battery limit valves which shall be suitable for operational and intelligent pigging with permanent / temporary launcher & receiver. Other Requirements: Valve in underground piping shall be easily accessible in concrete pits and it shall have extended stems. Regularly operated valves shall be accessible from grade or platform. Requirement for Gear operators shall be as specified in the applicable valve specifications and data sheets. Valves shall not be installed with their stem below horizontal plane, especially on liquid lines. Valve closing time shall be selected such that this will not cause detrimental stresses or high surge pressure in the piping system. Check valves shall not be installed in vertically downward flowing lines.

1


11.


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PIPELINE ANCILLARIES

11.1. PIPELINE TRACING All RTRP pipelines shall be spirally wrapped by contractor with a pipeline marking tape material containing a stainless steel strip for line detection with metal detectors. 11.2. PIPELINE MARKERS All pipeline markers shall be designed and installed in accordance with ASME B 31.4, ASME B31.8, API RP 1109, KOC standard drawing 55-04-67 and Project specifications. As a minimum all markers shall show the name of the pipeline, pipeline nominal diameter and pipeline chainage in both Arabic and English. The maximum distance between markers shall be 500M and at every change in direction as per clause 11.5 Appendix-F. Pipeline markers shall be located at all Road, Highway, track crossings and pipeline and utility crossings. Locations of the required markings shall be finalized during detailed design. For the buried section of the pipelines, combined CP test posts and pipeline markers shall be provided at each end of the crossing and at other locations as determined by the requirements of the CP system with reference to EWTIP-20PL-DGA-008.

11.3. PIPELINE WARNING SIGNS Generally, pipeline- warning signboards shall be provided at the following locations: Warning Signboards:  Aboveground and Underground pipelines and utility crossings. Warning, direction and danger signboards, as applicable, shall be installed at all Block Valve and Pig Launcher/Receiver Stations. All signboards and safety signs shall be designed and constructed in accordance with the typical drawings to be produced by CONTRACTOR and approved by COMPANY.

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PIPELINE DESIGN CRITERIA

12.1. GENERAL The design criteria for the project are based on providing safe, environmentally acceptable, low cost pipelines that are fit for their intended uses. All pipelines and facilities shall be designed to the codes and standards identified in this document and provide a 25-year service life. Steel pipelines shall be designed in accordance with ASME B31.4 / B31.8 as applicable. RTRP pipelines shall be designed in accordance with KOC standard for RTRP pipes and fittings: KOC-MP-011, part 1 and Engineering design and installation: KOC-MP-011 Part 2.

12.2. PIPELINE WALL THICKNESS CALCULATION Pipeline Wall thicknesses are to be based on Pressure containment and combined stresses plus corrosion allowance. The minimum selected wall thickness shall be based on the following: The OD/WT ratio maximum shall be ≤ 96 (land installation) External interference by third parties is not considered to be criteria for minimum pipe wall thickness as the pipeline shall be laid in designated pipeline corridors. The minimum wall thickness consideration shall be 6.35mm. The minimum thickness provided in FEED shall govern. The selected thickness during detailed engineering shall be greater than or equal to FEED thickness calculation.

Pipeline wall thickness shall be calculated as per ASME B 31.4 for hydrocarbon liquid services and as per ASME B 31.8 for hydrocarbon gas services as appropriate and pipeline stress shall be checked as per the code ASME B 31.8 & B 31.4

RTRP Pipeline wall thickness shall be per manufacturer standard based on design pressure & temperature provided in Appendix-1 of this design basis.

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12.3. DESIGN FACTOR Design factors to be used for calculating pipeline wall thickness shall be as given in following Table 12.1. Table 12.1: Design Factors Fluid

Design Factor

Effluent Water

0.72

Treated water

0.72

Fuel Gas

0.72 / 0.6 / 0.5

Distribution and Injection Pipelines / Flow lines

1

0.72

Brackish Water

0.72

Recovered Oil

0.72

12.4. STRESS CALCULATION AT ROAD CROSSINGS Stresses in pipeline at road crossings shall be checked using methods specified in API RP 1102, Steel Pipelines Crossing Railroads and Highways. Stresses shall be checked for fully corroded pipeline, i.e., after deducting corrosion allowance from the pipeline nominal wall thickness.

12.5. PIPELINE AT ABOVE GROUND / BELOW GROUND TRANSITION The Pipeline shall be subject to movements due to thermal expansion at the inlet / outlet of pig traps. This movement shall induce stresses in the pipeline and the connected above-ground piping. In order to limit the stresses within allowable limits, the pipeline movement at the above ground – below ground transition shall be reduced, either by providing adequate flexibility in the pipeline configuration at the approach to the scraper traps or by providing suitably-sized anchor blocks. The stress analysis shall be carried out and the pipeline movement shall be reduced as per detailed specification for pipeline flexibility analysis (14050642100-PL-SPC-0001).

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12.6. PIPELINE UPHEAVAL BUCKLING CHECK The expected operating temperature in general is between 30°C to 60°C. Hence pipeline upheaval buckling check is not envisaged in this project.

12.7. ON-BOTTOM STABILITY OF PIPELINES IN WET AREAS Generally, Pipelines shall be installed on a raised embankment made of gatch to elevate them above the water level in sabkha areas. Where concrete weight coating is to be applied to a pipeline for stability purpose, the required concrete coating thickness shall be established based upon the following assumptions: Pipeline in the air filled condition. Specific gravity of underlying wet soil with a factor of safety against flotation of 1.25. The on-bottom stability calculations for pipelines in wet areas are performed in accordance with the following equation: W air > 1.25 W

buoyancy

Where

Wbuoyancy

= Buoyancy of air filled pipeline relative to liquefied ground

Wair

= Weight of pipeline in air

The pipelines shall be designed to be stable over the design life. This shall be achieved by increasing the weight of concrete coating to give the desired factor of safety. Concrete is assumed to have a density of 2240 Kg/m 3 and in all cases the minimum thickness shall be 40mm. Temporary stabilization during construction shall be considered. Soil weight when buried should be considered for operational cases.


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PIPELINE ROUTING A pipeline route survey shall be carried out prior to producing detailed route alignment sheets which will include topographical, geotechnical and underground investigation. The horizontal clearance between the pipelines and the existing cable shall meet KOC-E-008 & KOC-L-002 requirements. All pipelines installed in the new pipeline corridors will have 1 m berm constructed from natural ground level for protection. The information included in the drawings, documents, specifications and alignment sheets must be reviewed fully to appreciate the extent of the design parameters. All pipeline corridors depending on the number of pipelines to be installed will have permanent six meter access tracks constructed along each pipeline corridor to be used for pipeline construction and also for permanent maintenance roads after construction activities are completed. The location of permanent access tracks shall be shown on the Pipeline Route Alignment sheets. No sectionalizing valves will be required on any of the routes of the pipelines for intermediate isolation. There are numerous rig track, gatch and asphalt road crossings, above and below ground utilities to be crossed on all of the pipeline route corridors. The minimum distance from the base of any power pylon shall be 20 meters as per clause 11.4.2 of KOC-L-002. Where the pipeline runs parallel with a buried power cable, the horizontal clearance between the pipeline and the existing cable shall not be less than 3 meters. This shall be increased where there is a likelihood of CP interference. A Cathodic protection system shall be designed and installed on all steel buried pipelines. A corrosion monitoring study shall also be carried out to review any corrosion monitoring requirements on the various pipelines. All carbon steel pipework will be externally coated along with the welded joints. All carbon steel pipework will be welded to sour service conditions. It is to be aware that there are other CONTRACTORS, working in the area along with well drilling, road construction and other third party activities in North Kuwait. Therefore interface is required with other CONTRACTORS to avoid any disruption or impact to their work which would cause delay to their schedule.


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All pipelines shall be hydro tested to KOC and International Standards. pipeline stress analysis shall be carried out on the various pipelines up to and including the pig launcher/receivers in the various installations to take into account the various Design Code breaks to confirm anchor blocks design requirements.

13.1. GENERAL APPROACH The principal strategy adopted in finalizing pipeline routes involved, 

Shortest connections to minimize route lengths.



Avoiding or minimizing disturbances to natural environment, ecology etc.



Construction feasibility maintaining adequate clearance between the existing facilities.



Existing or planned pipelines, facilities and cables



Obstructions, soil conditions and grade changes



Proposed intermediate isolation valves, if any



Temporary access for construction



Uninterrupted permanent access for maintenance



Crossings of existing roads or tracks or with other existing pipelines / cables



Utilization of existing right of way and crossings



Security from accidental or deliberate interference from Third Parties



Avoidance of excessively corrosive environments



Availability of power supplies.



Seasonal water courses and locations susceptible to washout and contaminated soil areas.

Care shall be taken to follow existing pipeline routes and corridors where ever possible, and to minimize the number of hot bends for ease of installation.

13.2. ROUTE ALIGNMENT SHEET The route alignment sheets shall be developed and shall contain the following



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detailed data: 

Route layout, ground profile, topography, soil condition/characteristics;



Location of existing above ground and buried pipelines, location of existing power cables, overhead lines and other services



Soil resistivity measurement for CP design and Cathodic protection



Change of Design code & design factor , line pipe material, grade and wall thickness,



Design conditions, Hydrostatic test sections and Test Pressure



Surface/ terrain details, track, asphalt/rig track crossings, area of high water table



Bench marks and survey references



Pipeline markers and warning signs



Coating type, buried depth, special items (Valves, fittings, hot bends,

1

insulation joints etc.) 

Type of construction, crossing location, types and applicable drawings



Location of oil wells / lakes / buildings / KOC facilities within 250m from the center line of the pipeline corridor



Location of pig traps & signalers



Location of Man way / Hand hole, Valve Pits and pipeline markers.



Key Plan



Detailed ROW section views, wherever required.

1

13.3. TERRAIN AND INSTALLATION The pipeline shall be buried with minimum cover in accordance with EWTIP-20PL-SPC-0002 & 15-IH-1002 Pipeline design and appropriate for the location as detailed in EWTIP-20-PL-SPC-0008 & KOC-L-0002 – Recommended Practice of KOC Services: Clearance Requirements for Buried Pipelines and Piping, Cables, Underground Structures and buildings. Sudden gradient changes in the pipeline profiles shall be avoided where possible in order to minimize the occurrence of low points.


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Pipelines shall be constructed on the ground or if the area consists of marshlands, swamp or has a high water table then the ground level shall be raised using gatch. The pipelines shall be covered with one meter high berms of sand and if the area is subject to wind erosion then a layer of gatch shall be used to protect the berms. Where pipelines cross existing services, the new pipelines shall pass underneath with a minimum vertical separation distance of 1m from the underside of the existing service to the top of the new pipeline or service. Construction of Pipelines shall confirm the requirements of Project specification for Pipeline Construction, EWTIP-20-PL-SPC-0018 & 015-IH-1001.

13.4. SEPARATION DISTANCES AND EXCLUSION ZONES Pipeline Burial depth and Clearances shall be in accordance to COMPANY specification KOC-L-002 and EWTIP-20-Pl-SPC-0008.

1

13.4.1. PIPELINE SEPARATION DISTANCE WITHIN CORRIDORS Within corridors where pipelines are laid parallel to one another in a trench or alongside / across existing services the pipelines are required to be laid by a minimum distance as required in Table 13.1.

Table 13.1 Pipeline Separation within Corridors Minimum Separation Pipeline Condition Pipelines laid in same trench (alongside each another) Pipelines

installed

in

plants #

at

plant

Horizontal

-

1m

-

5m #

separate

trenches (new or existing lines) except

Vertical

approaches/near


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CONTRACT NO. 14050642 PIPELINE DESIGN BASIS Doc. No. : 14050642-100-PL-DBM-0001 Mechanical

Equipment

operation

-

5m**

-

20m*

-

0.5m

1.0 m

-

parallel to existing pipelines** Pipelines that run parallel with power lines* Pipeline in the same trench as Fiber Optic Cable Pipeline or existing service and cable buried crossings

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*For distance between pipelines and overhead lines shall be as per clause 11.4.3 of KOC-L-002. **For protection of existing services during construction in accordance with clause 17.0 of KOC-L-002. # The distance can be further reduced upto 1m with manual excavation. 13.4.2. PIPELINE BURIAL DEPTH Minimum cover for pipelines shall be generally 1 m from grade elevation; however it shall be 1.2m under field roads as per clause 17.3.8 of KOC-L-002. Pipeline burial depth from ground surface to top of pipe shall be as per table 13.2 below Table 13.2 Pipeline Burial Depths Location

Minimum Cover

Normal Terrain and sand Dunes

1.0 m

Minor road / Track Crossing (Uncased)

1.2 m

Asphalt Road and Rig Track crossings(Cased)

1.2 m*

Sabkha crossings/ High Water table Areas (Note1)

1.5 m

* Minimum cover from top of casing pipe. Note 1: No high water table / Sabkha areas are identified in this project. Note that the above indicated cover values are the minimum between top of pipe and natural ground surface. In addition, pipelines shall have



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berm with 1m height. Final requirements of cover height shall be verified by flexibility analysis. Note 2: The above mentioned cover for Asphalt Road and Rig Track crossing shall be confirmed with road crossing calculation.

13.4.3. PIPELINE CROSSING A Crossing Design Report shall be prepared and submitted to COMPANY by CONTRACTOR detailing each asphalt road and rig tracks crossing type and method of construction / installation. Crossings shall be suitably designed to API 1102 to prevent any traffic load onto the pipeline and also in accordance with KOC-L-002 Specification. It shall also be suitably designed for electrical influences between the services by using adequate clearance or any other suitable means. Where multiple pipelines are installed adjacent to each other in the same pipeline corridor, the minimum clear spacing at the trenchless road crossings shall be 3 meters. The pipelines shall be designed to prevent expansion or contraction causing excessive forces or stresses in the pipeline system. Pipe sleeves used for Asphalt road and rig tracks crossing installations shall be bare (uncoated) metallic pipe in accordance with clause 7.8.1 of KOC specification KOC-L-015 Rev.2. The crossing of rig track, gatch and paved roads shall be in accordance with KOC standard 381 / 13 Part 1. Field desert tracks, gatch and rig track can be crossed by open cut construction with approval from COMPANY. For RTRP pipeline, metallic sleeves shall be provided at road & track crossing. Pipelines shall be protected at crossings as per API 1102 & KOC-L-002. However subject to Company approval, direct burial is acceptable if Contractor can demonstrate in accordance with API 1102 that the strength of metallic carrier pipe is sufficient without protection by sleeve pipe at road crossing. In addition the carrier pipe wall


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thickness shall meet the applicable Code requirements for road crossing. Sleeve pipe shall be sealed at each end with “Pull-On” type end seals to prevent ingress of soil / water. Major Asphalt road crossings shall be based on trenchless installation method using non-open cut techniques like horizontal directional drilling, auger-boring, thrust-boring or microtunneling techniques. But subject to approval by COMPANY, Open Cut shall be carried out. Crash Barriers shall be installed at all road crossings to protect the installed pipeline and crossing vents from Third Party damage in accordance with the drawings. All crossing methods shall be subject to COMPANY approval. Pipeline safety shall be checked in accordance with API 1102 – Steel Pipeline Crossing Railroads and Highways. all road crossings shall be recorded during Topographic survey. New pipelines shall be buried below existing pipelines with a minimum clearance of 1.0m, unless otherwise agreed by the COMPANY. All Major asphalt

road crossings shall be made at an angle of 90

degree to the road Centre line by an approved ‘non-disruptive’ road crossing method of carrier pipe without any casing if approved by COMPANY. Specific crossing drawings shall be created for each major crossing. The minimum pipeline burial depth for the general route, road and track crossings as given in table 13.2. The following wheel loadings were taken into account in determining the stresses imposed on the carrier pipe / casing pipe at each crossing: 

Asphalt Road / Highway / Track crossings: As per KOC specification 015-IH1002, 112kN per wheel at 900mm centers with maximum of four (4) wheels per axle. Contact area per API RP 1102 is 0.093 square meters, giving surface pressure = 1204 kN/m2. Rig Track crossings: The total load of rig is 1100 KN and the maximum Tandem axle wheel load is 550KN. The contact area, over which the wheel load is applied, shall be taken as 0.403 square meters.

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The number of crossings of roads, tracks, pipelines, and other services by new replacement pipelines and their right of way access tracks shall be minimized. Access across the new and replacement pipelines shall be by existing roads and tracks. Where no suitable road or track exists, crossing points at intervals no greater than 1 Km shall be provided as per clause 9.11of 015-IH-1001. For pipelines running alongside other (existing) pipelines, crossing points shall be at the location of existing crossings. Number of crossings and locations shall be reviewed and approved by COMPANY. Pipe strings welds shall be subjected to 100% radiography or 100% ultrasonic testing and hydro tested prior to incorporation into a nondisruptive crossing. The method employed to handle coated pipe and insert the coated line pipe into non-disruptive crossing shall be such that damage to coatings and field joints shall not be there. Pipe sleeves shall be in reference to standard drawing 55-04-77.

13.4.4. FOREIGN SERVICES

All foreign services and underground utilities that are crossing or encroaching in the pipeline corridor shall be located, recorded and protected. CONTRACTOR to confirm position and depth of all utilities shown on the alignment sheets and also any utilities found during detailed survey or during construction activities are the responsibility of CONTRACTOR. All crossings shall be installed as per typical drawings. All new pipelines shall be installed below existing foreign services unless otherwise agreed by the Company. The crossing of existing buried pipelines, cables, power lines and minor roads shall be as below table.


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Minimum Crossing

Crossing

Angle

Existing pipelines and cables,

60° (note-1)

Unimproved roads, track & Asphalt roads Overhead power lines

90° (note-2)

Notes: 1. Wherever it is not feasible to maintain minimum 60°, the crossing angle between proposed pipeline and existing pipeline / cables 1

can be reduced up to minimum 30°. 2.

Wherever

underground

pipeline

crosses

overhead

power

transmission lines, it shall be preferably be at right angle (90°). In unavoidable locations, the horizontal angle of intersection shall be maintained within 70° to 110° to the overhead power line.

13.4.5. PIPELINE CROSSING DRAWINGS Detailed crossing drawings shall be generated for major asphalt road crossings based on confirmed alignment of pipelines as per topographic and geotechnical survey findings shall be provided. The crossing drawings shall include as a minimum: 

The road / track / ROW / pipelines / utility / feature to be crossed in relation to the pipeline.



Profile including bend information and depth of cover (if applicable).



Plan, at a scale not greater than 1:500.



COMPANY

requirements,

including

minimum

protection requirements, etc. 

Cathodic Protection details.



Pipeline markers.



Line size, material grade and wall thickness.



Crossing co-ordinates.



Proposed method of Construction / Installation

clearances,



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13.4.6. PIPELINE PRESERVATION: Pipeline preservation is not envisaged for this project. However, if required, the pipeline preservation shall be carried out for Fuel Gas Pipelines after construction, and hydro testing activities are completed. The fuel gas carbon steel pipelines at the termination points of the pipelines at the various installation boundary fences shall have welded steel caps on the ends of the last pipe along with a 2 “ ball valve .The pipelines shall be filled with nitrogen to a pressure of one barg and this internal pipeline pressure shall be monitored to check that there is a positive pressure in the pipeline until it is connected to the installation facility pipeline. A temporary CP system must be installed and working on the pipelines until a permanent CP system is designed and commissioned. HDPE lined water injection pipelines, FBE lined recovered oil pipelines and Pipelines constructed of RTRP do not require nitrogen preservation.

13.5. TOPOGRAPHICAL & GEOTECHNICAL DATA Topographic survey drawings, reports and geotechnical reports shall comply with Project requirement as defined in scope of work for Topographical & Geotechnical survey for Pipeline route corridor.

14.

DESIGN PHILOSOPHY AND PHYSICAL DATA

14.1. PIGGING, HYDRO TESTING & INSPECTION All carbon steel pipelines shall have a hydro test of 1.25 times the design pressure in accordance with ASME B31.4 for water injection pipelines. Fuel gas pipeline shall be hydro tested at 1.25 times the design pressure as per table 841.3.2-1 ASME B31.8. All RTRP pipelines shall have a hydro-test at 1.5 times the design pressure for a period of 30 minutes as a strength test followed by a hydro-test at 1.33 times


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the design pressure for a period of 8 hours in accordance with KOC standards for RTRP Pipes & Fittings: Engineering Design and Installation, KOC-MP-011 part 2 or as required by company. The Water injection lines, Recovered Oil lines and Fuel Gas Lines shall be designed as piggable. For details and the requirement of permanent or temporary pig traps on the individual systems refer schematic drawing. Pipeline pigging and hydrostatic testing shall be carried out in accordance with KOC Standard 015-IH-1004 and associated Project Addendum EWTIP-20-PL-SPC0015.

14.2. NON DESTRUCTIVE TESTING In road crossing, populated areas, Tie-ins and weld repair locations, All butt welds shall be subjected to 100% X-ray radiography or UT and all fillet welds shall be 100% tested with liquid penetrant / wet magnetic particle crack detection method in accordance with company specifications 015-IH-1008 and 015-WH-1002.

14.3. PIPELINE DEWATERING AND DRYING Pipeline dewatering and drying shall be conducted in accordance with KOC Standard 015-IH-1005 and associated Project Addendum EWTIP-20-PL-SPC0016.

14.4. FIRE AND SAFETY REGULATIONS All relevant safety requirements of KOC’s Fire and Safety Regulations and KOC’s HSE policy Shall be adhered to while performing the works within KOC pig-trap areas and pipeline route.

14.5. SITE TIE-IN REQUIREMENTS The associated pipeline facilities required at tie-in sites include other valves and piping. These facilities, up to the code break locations identified on the P&IDs, shall be designed in accordance with ASME B31.4.


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Positive isolation by spading / blinding shall be used for welded tie-ins. All tie-in locations shall be identified and a tie-in schedule produced. It shall be confirmed that the connecting piping is adequately protected from overpressure of the pipeline. Hot tapping shall be in accordance to KOC-MP-038: KOC recommended practice for hot-tapping and plugging. 14.6. STRUCTURAL INTEGRITY: The pipelines shall be checked for structural integrity taking into account the anticipated stress conditions in the pipeline during installation, hydrostatic testing and operation. As a minimum the following calculations/checks shall be performed. 

Internal pressure



Pipeline road and track crossing analysis in accordance with API 1102



Pipeline stress analysis



Pipeline flexibility and tie-in analysis for above ground pipe work

The stress analysis of the pipeline system shall be performed using the latest version of Caesar II program and evaluated in accordance with the governing code requirements. The stress analysis shall be carried out as per detailed specification for pipeline flexibility analysis (14050642-100-PL-SPC-0001).

15.

WELDING REQUIREMENTS

Welding shall be in accordance with API 1104: Welding of Pipelines and Related Facilities, in conjunction with Project Specification EWTIP-20-PL-SPC-0002: Addendum to KOC specification: Pipeline Design (015-IH-1002, rev.1), EWTIP-20-PL-SPC-0018: Addendum to KOC specification for pipeline construction (015-IH-1001, rev.1). It shall be in line with company standards 015-IH-1008, 015-IH-1001 and 015-IH-1002. For sour service pipeline welding, a project specific welding specification is developed and followed. Refer Document No: Weld key plan / Weld table: 14050642-700-QA-PRO0045.

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16.

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TESTING AND PRE-COMISSIONING

During the detail engineering phase of the project the optimum method of pipeline testing and pre-commissioning shall be developed which shall take into account method(s) of test water supply and disposal, dewatering, required level of dryness, method of pipeline drying and introduction of product into the pipeline. Reference shall be as per the Philosophy for cleaning, Gauging, Hydro testing, Dewatering, Drying and Purging of Flow lines/ Pipelines. The cleaning, gauging, testing, drying and pre-commissioning activities shall be performed generally in accordance with the above philosophy and Company specifications 015-IH-1004 and 015-IH-1005 with Project Addendums EWTIP-20-PL-SPC-0015 and EWTIP-20-PL-SPC-0016. 17.

CORROSION PROTECTION

17.1. CATHODIC PROTECTION The underground pipelines shall be protected by the application of highintegrity

coating

systems supplemented with impressed current cathodic

protection (ICCP). Temporary CP utilizing sacrificial anodes shall be used to protect the pipelines during construction, and prior to commissioning of the permanent ICCP systems. CONTRACTOR shall carry out a detailed corrosion study to confirm the requirements for corrosion fittings, corrosion monitoring sample pits and locations along the various pipelines. Reference shall be made to

company

specification

KOC-MP-035:

Internal

Corrosion

Monitoring

Equipment for Facilities and Pipelines. Insulating flange joints shall be provided at the location of underground to aboveground transition of pipelines and wherever applicable as per clause 7.11 of KOC-L-015 for cathodically protected pipelines. All carbon steel pipelines will be electrically isolated from pigging facilities by a properly designed cathodic isolation device downstream of the bypass tee. Pipeline/piping portions including valves and flanges in valve pits shall be protected against corrosion to KOC standards and ensure integrity of cathodic



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protection system. All pipe supports shall ensure integrity of cathodic protection system. Cathodic protection shall be installed to provide the level of protection required by the KOC standard KOC-L-015.

17.2. EXTERNAL CORROSION

17.2.1. COATING The carbon steel pipes shall be externally coated with a shop applied dual-layer fusion bonded epoxy corrosion coating as per company specification KOC-P-004 part 4 rev.2 and field joint external coating for girth welds, pipeline fitting and flanges shall be protected with fusion bonded epoxy coating as per company specification KOC-P-004 part 7, rev.2. Above ground installations shall be in accordance to Company standard KOC-P-001. Coating thickness DFT and other characteristics shall comply to Table1 and Table-3 of KOC-P-004 part 4 rev.2



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ATTACHMENT-1: PIPELINE SCHEMATIC DIAGRAM

54 of 54 0 17.06.2015

14050642 100 PL DBM 0001_Pipeline Design Basis_Rev 1

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